Goldstar M5403R manual

ROOM AIR CONDITIONER SERVICE MANUAL CAUTION BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. website: http://www.lgservice.com e-mail: http://www.lgeservice.com/techsup.html MODEL : M5403R, M5203R, M5203L, M6003R, WM-6011, LWJ0611PCG, LWC061JGMK1 D r y F a n C o o l[...]

—2— CONTENTS 1. PREF A CE ................................................................ 2 1.1 FEA TURES.................................................................. 2 1.2 SPECIFICA TIONS ...................................................... 3 1.3 SAFETY PRECA UTIONS ........................................... 3 1.4 INSULA TION RESIST A[...]

1.2 SPECIFICA TIONS • NO TE: Specifications are subject to minor change without notice f or fur ther improv ement. —3— MODELS ITEMS COOLING CAP ACITY (BTU/h) 5,300 5,200 5,200 6,000 6,000 PO WER SUPPL Y (Phase, V , Hz) 1ø , 115V , 60HZ INPUT (W) 530 470 610 620 OPERA TING CURRENT (AMP .) 4.8 4.3 5.6 5.8 REFRIGERANT CONTROL CAPILLAR Y TUBE RE[...]

—4— 1.5 LOCA TIONS OF CONTROLS 1.5.1 CONTROLS Dry Fan Cool ON/OFF TIMER - STOPPING OPERATION • Everytime you push this button, when the unit is operating, timer is set as follows. (1Hour 2Hours 3Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel) • The Setting Temperature will be raised by 2 ° F(1 ° C) 30min. l[...]

— 5 — 1.5.2 REMO TE CONTROLLER How to Insert Batteries 1. Remov e the cover from the bac k of the remote controller 2. Inser t two batteries. • Be sure that the (+) and (-) directions are correct. • Be sure that both batteries are new . 3. Re-attach the cov er . • Do not use rechargeab le batter ies. Such bat- teries diff er from standard[...]

— 6 — 2. DISASSEMBL Y INSTR UCTIONS 2.1 MECHANICAL P AR TS 2.1.1 FRONT GRILLE 1. Disconnect the unit from source of power . 2. Using a screwdriv er , remov e 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 aw a y from the cabinet as the top ta[...]

— 7 — 2.2 AIR HANDLING P AR TS 2.2.1 AIR GUIDE UPPER 1. Disconnect the unit from the power source . 2. Remov e the front grille. (Refer to Section 2.1.1) 3. Remov e the cabinet. (Refer to Section 2.1.2) 4. Remov e the control board. (Ref er to Section 2.1.3) 5. Remov e 2 screws that secure the air guide upper to air guide lower . (See Figure 6)[...]

— 8 — 2.2.3 MO T OR 1. Disconnect the unit from the power source . 2. Remov e the front grille. (Refer to Section 2.1.1) 3. Remov e the cabinet. (Refer to Section 2.1.2) 4. Remov e the control board. (Ref er to Section 2.1.3) 5. Remov e the air guide upper . (Ref er to Section 2.2.1) 6. Remov e the compressor , turbo fan, f an and shroud. (Ref [...]

— 9 — 2.3.2 COMPRESSOR 1. Remov e the front grille and cabinet. (Ref er to Section 2.1.2) 2. Discharge the refrigerant by using a refrigerant recov er y system. 3. Remov e the overload protector . (Ref er to Section 2.3.1) 4. After discharging the unit completely , unbrace the suction and discharge pipes at the compressor connections. 5. Remov [...]

— 10 — 2.3.6 PO WER CORD 1. Disconnect the unit from source of power . 2. Remov e the front grille. (Refer to Section 2.1.1) 3. Remov e the cabinet. (Refer to Section 2.1.2) 4. Remov e 2 screws that secure control board to base pan and orifice. 5. Pulls the control board tow ard you. 6. Remov e the grounding screw . 7. Remov e a screw securing [...]

2.4.3 CAPILLAR Y TUBE 1. Remov e the cabinet. 2. Discharge the refrigerant by using a refrigerant recov er y system. 3. Remov e the air guide upper . (Refer to Section 2.2.1) 4. After discharging the refrigerant completely , unbraze the interconnecting tube of the capillary tube. 5. Remov e the capillar y tube. 6. Re-install by ref erring to the pr[...]

— 12 — Equipment needed: V acuum pump , charging cylinder , manifold gauge, br azing equipment, pinch-off tool capable of making a vapor proof seal, leak detector , tubing cutter , hand tools to remov e components and ser vice v alve. B A B A B A COMPOUND GAUGE SEE INSETS BELOW CAPILLARY TUBE EVAPORATOR (LOW PRESSURE SIDE) COMPRESSOR CONDENSER [...]

— 13 — 3. INST ALLA TION This air conditioner is designed with a button-down chassis so it can be easily installed in a window . 3.1 SELECT THE BEST LOCA TION 1. T o prev ent vibration and noise, mak e sure the unit is installed securely and firmly . 2. Install the unit where the sun does not shine directly on the unit. 3. The outside of the ca[...]

— 14 — Installation 3.2.2 BEFORE INST ALLA TION 1. Inser t the guide panels into the guides of the air condi- tioner . F asten the cur tains to the unit with scre ws (TYPE A) as shown Figure . 24. 2. Cut the adhesive-bac ked seal strip (TYPE D) to the window width. Remov e the backing from the seal strip and attach the seal strip to the undersi[...]

3 . INST ALL THE AIR CONDITIONER IN THE WINDO W a. Carefully lift the air conditioner and slide it into the open window . Make sure the bottom guide of the air conditioner drops into the notches of the L brac ket. See Figure . 27. IMPORT ANT : When the air conditioner drops into the L brack et, the air conditioner will be centered in window opening[...]

— 16 — REMO V AL FROM WINDO W T ur n the air conditioner off, disconnect the po wer cord, remov e the L brac ket and the scre ws installed through the top and bot- tom of the guide panels, and sa ve f or reinstallation later. Close the guide panels . Keeping a firm grip on the air conditioner , raise the sash, and carefully tilt the air conditi[...]

— 17 — 4.2 PIPING SYSTEM F ollowing is a brief description of the impor tant components and their function in what is called the refrigeration system. Ref erence should be made to Figure 32 to f ollow the refrigerating cycle and the flow of the refrigerant in the cooling cycle. COOLED AIR HOT DISCHARGED AIR MOTOR COMPRESSOR ROOM AIR HEAT LOAD C[...]

— 18 — 4.3 TR OUBLESHOO TING GUIDE In general, possib le trouble is classified in tw o kinds. The one is called Starting Failure which is caused by an electrical defect. The other is Ineffective Air Con- ditioning caused by a def ect in the refrigeration circuit and improper application. Unit is running but cooling is ineff ective . Ineffective[...]

— 19 — Fails to Start Improper ther mistor setting Loose ter minal connection Improper wiring Check of po wer source. Drop of power v oltage. Capacitor check. Replacement. Check of control panel setting. Compressor f ails only to star t. Def ect of compressor capacitor . Replacement of compressor (Motor damaged). Irregular motor insulation ( ?[...]

— 20 — Is the Trans output power AC 115V? Is the Trans output power about AC 14V? Is shorted the Trans. output? Is output Voltage of IC01D DC 12V? Is output Voltage of IC02D DC 5V? Is the voltage No.20 of Micom DC 5V? Exchange Main P.W.B Ass'y. Is the connection between Main and Display all right? Is the reset circuit all right? (The No.16[...]

— 21 — Is Temp. setting set lower than Room Temp.-0.5 ° C? Is the voltage No.11 of IC01M 0V? • Exchange IC01M. • Set the Temp. setting to higher Temp. • Wait 3 Minutes Is the Unit for 3 minutes delay? • Exchange MAIN P.W.B Ass'y. Is the voltage N0.6 of IC01M DC 5V? • Check the RY-COMP. • Check the wiring Diagram. NO NO NO NO Y[...]

— 22 — Is the voltage of Battery about over 2.3V? • Exchange Receiver Ass'y. Is the connection of CN-DISP2 all right? Is the voltage No.10 of CN-DISP2 on Main P.W.B Ass'y DC 5V? • Exchange the battery. • Check the P.W.B pattern. • Connect connector to CN-DISP2 exactly. NO NO NO YES YES YES P ossible T rouble 5 • Romote contr[...]

— 23 — ROOM AIR CONDITIONER V OL T A GE LIMITS NAME PLA TE RA TING MINIMUM MAXIMUM 115V ± 10% 103.5V 126.5V COMPLAINT CA USE REMED Y F an motor will not run. No power Check v oltage at outlet. Correct if none. P ower supply cord Check v oltage to rotar y s witch. If none, check power supply cord. Replace cord if circuit is open. Rotar y s witc[...]

— 24 — COMPLAINT CA USE REMED Y F an motor noise. F an If crac ked, out of balance , or par tially missing, replace it. Blower If crac ked, out of balance , or par tially missing, replace it. Loose set screw Tighten it. W orn bear ings If knocking sounds contin ue when running or loose, replace the motor . If the motor hums or noise appears to [...]

— 25 — COMPLAINT CA USE REMED Y Compressor cycles on F an motor If not running, deter mine the cause. Replace if ov er load required. Condenser air flow Remo ve the cabinet, inspect the interior surf ace restriction of the condenser . If restricted, clean carefully with a vacuum cleaner (do not damage fins) or brush. Clean the inter ior base be[...]

— 26 — LOCA TION NO . 1 2 3 4 5 6 7 8 5. SCHEMA TIC DIA GRAM 5.1 CIRCUIT DIA GRAM • MODEL : M5403R, M5203R, M5203L, M6003R, WM-6011, L WJ0611PCG, L WC061JGMK1 Q'TY PER SET 1 1 1 1 1 1 1 1 DESCRIPTION PO WER CORD ASSEMBL Y F AN MO TOR COMPRESSOR DISPLA Y P .W .B ASSEMBL Y MAIN P .W .B ASSEMBL Y THERMIST OR CAP ACIT OR O WERLOAD PR O TECT [...]

— 27 — 5.2 ELECTRONIC CONTR OL DEVICE[...]

— 28 — 5.3 COMPONENTS LOCA TION (FOR MAIN P .W .B ASM) 5.4 COMPONENTS LOCA TION (FOR DISPLA Y P .W .B ASM)[...]

— 29 — 6. EXPLODED VIEW 135313 352390 267110 152302 130410 359012 W48602 135312 354210 349480 352380 149980 559011 346811 554030 W48602 130910 264110 238310 W0CZZ 249950 268714 263230 550140 554160 567502 352115 552111 352113 35211A 237200 268712[...]

— 30 — 7. SER VICE P ARTS LIST LOCA TION NO DESCRIPTION REMARKS M5403R M5203R M5203L 130410 BASE ASSY , SINGLE 3041A10011E R 130910 CABINET ASSY ,SINGLE 3091A10020A R 135312 GRILLE ASSY , FRONT(SINGLE) 3531AR1644H 3531AR1644U R 135313 GRILLE ASSY , INLET 3530A10039A R 137215 P ANEL, CONTROL 3720A20017A 3720A20111A R 149980 SHR OUD 4998A10006A 4[...]

— 31 — M6003R WM-6011 L WJ0611PCG L WC061JGMK1 130410 BASE ASSY , SINGLE 3041A10011E 3041A10011E 3041A10011E 3041A10011E R 130910 CABINET ASSY , SINGLE 3091A10020A 3091A10020A 3091A10020D 3091A10020D R 135312 GRILLE ASSY , FRONT(SINGLE) 3531AR1644H 3531AR1644T 3531AR1644T 3531AR1644T R 135313 GRILLE ASSY , INLET 3530A10039A 3530A10039A 3530A100[...]

P/No.: 3828A20038B February, 2003 Printed in Korea[...]