LG Electronics General Wall Mounted-Inverter Type manual

Room Air Conditioner SVC MANUAL(General) MODEL : General Wall Mounted-Inverter Type CAUTION Before Servicing the unit, read the safety precautions in this SVC manual. Only for authorized service personnel. http://biz.lgservice.com[...]

2 Room Air Conditioner Air Conditioner Ser vice Manual CONTENTS P art 1 General Information 1. Safety Precautions ........................................................................................................4 2. Nomenclature ............................................................................................................... 7 [...]

Ser vice Manual 3 1. Safety Precautions ......................................................................................................... ...4 2. Nomenclature ......................................................................................................................7 P ar t 1 General Inf ormation[...]

4 Room Air Conditioner P ar t 1 General Inf ormation 1. Safety Precautions 1.1 Cautions in Repair To prevent injury to the user or other people and property damage, the following instructions must be followed. ■ Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the follow- ing indications.[...]

Ser vice Manual 5 P ar t 1 General Inf ormation Do not tur n on the break er when the front panel and cabinet are remov ed. Be sure to ground the air conditioner with an ear thing conductor connected to the ear thing ter minal. Conduct repair works after checking that the refrigerating cycle section has cooled down sufficiently . Otherwise , workin[...]

6 Room Air Conditioner P ar t 1 General Inf ormation Check to see if the par ts are mounted correctly and wires are connected. Improper installation and connections can cause an electric shock or an injur y . Check whether the installation platf orm or frame has corroded. Corroded installa- tion platf or m or frame can cause the unit to f all, resu[...]

Ser vice Manual 7 P ar t 1 General Inf ormation 2. Nomenc lature 2.1 Global Model Name Code Type Code of Model Meaning 1 Production Center, A~Z L: Chang-won R22 Refrigerant A: Chang-won R410A 2 Product Type A~Z S: Split Type Air Conditioner 3 Cooling/Heating/Inverter A~Z C: Cooling Only H: Heat Pump X: C/O + E/Heater Z: H/P + E/Heater V: AC Inverte[...]

8 Room Air Conditioner P ar t 2 Functions & Contr ols 1. List of Controls & Functions ..........................................................................................9 2. Basic Mode Controls ......................................................................................................10 3. Special Mode Controls ...........[...]

Ser vice Manual 9 P ar t 2 Functions & Controls 1. List of Functions & Contr ols Cooling Mode Heating Mode Healthy Dehumidification Automatic operation Auto Changeover Jet Cool Jet Heat Energy saving Forced operation Auto Clean Air volume control Natural Air control Chaos Swing Sleep mode Auto control Auto Restart Function Five Second Delay[...]

10 Room Air Conditioner P ar t 2 Functions & Controls 2. Basic Mode Contr ols 2.1 Cooling Mode Setting Temp. -0.5 ° C(-1 ° F) +0.5 ° C(1 ° F) Comp. OFF Thermo ON Thermo OFF INV. Comp. Frequency Low High Low High • Operating frequency of compressor depends on the load condition, like the difference between the room temp. and the set temp.,[...]

Ser vice Manual 11 P ar t 2 Functions & Controls 2.3 Health y Dehumidification operation • When the dehumidification operation is set by the remote controller, the intake air temperature is detected and the set- ting temp. is automatically set according to the intake air temperature. • When intake air temp. is 1 C(2 F) above the setting tem[...]

12 Room Air Conditioner P ar t 2 Functions & Controls 3. Special Mode Contr ols 3.1 Jet Cool operation • In the heating mode or Fuzzy operation, the Jet cool function does not work. When it is input while in other mode of operation (cooling, dehumidification, ventilation), the Jet cool operation takes place. • In the Jet cool mode, the indo[...]

Ser vice Manual 13 P ar t 2 Functions & Controls 4. Utility Functions 4.1 For ced operation • To operate the appliance manually in case when the remote control is lost, the forced operation selection switch is on the main unit of the appliance, and operate the appliance in the standard conditions. • The operating condition is set according [...]

14 Room Air Conditioner Mode2 Mode3 Mode4 Mode5 Mode6 Mode7 Mode8 Mode9 OPEN CLOSED 8 ° Cooling Operation 120 ° Mode2 Mode3 Mode4 Mode5 Mode6 Mode7 Mode8 Mode9 OPEN CLOSED 8 ° Heating Operation 120 ° Mode1 Mode1 Mode2 Mode3 Mode4 Mode5 Mode6 Mode7 Mode8 OPEN CLOSED 8 ° Cooling Operation Mode1 Mode2 Mode3 Mode4 Mode5 Mode6 Mode7 Mode8 OPEN CLOS[...]

Ser vice Manual 15 P ar t 2 Functions & Controls 4.6 Sleep mode A uto contr ol • When the set sleep time is reached set time of [1,2,3,4,5,6,7hour] input by the remote control during the operation, the operation of the appliance stops. • When the appliance is on pause, the sleep timer mode cannot be input. 4.6.1 Sleep timer operation for co[...]

16 Room Air Conditioner P ar t 2 Functions & Controls 5.1 Five Seconds Stand-b y (fan) • The indoor unit fan rotates after 5 seconds when unit is turned on. 5.2 T w o Minutes Stand-b y (comp.) • Compressor starts two minutes later, after it is turned off 5.3 Hot star t • When unit starts in the heating mode to prevent cold wind blowing, t[...]

Ser vice Manual 17 P ar t 2 Functions & Controls 5.5 A utomatic defr ost 5.5.1 9,12kBtu/h Model • While in heating mode operation in order to protect the evaporator pipe of the outdoor unit from freezing, reversed to cooling cycle to defrost the evaporator pipe of the outdoor unit. • Defrosting control is available 40 minutes later since he[...]

18 Room Air Conditioner P ar t 2 Functions & Controls 5.5.2 18,24,30kBtu/h Model • Starting to the defrosting operation 1) Defrost operation will be start when the conditions below are matched a) Accumulation time of operation and the period after completion of defrost = 35 min. b) After 10 minutes from re-starting the compressor .In case of [...]

Ser vice Manual 19 P ar t 2 Functions & Controls • Defrosting Contr ol Algorithm 1) Lowering the compressor frequency when starts the defrosting operation. Constant speed compressor is ON after 10 seconds from the arrival time of 30 Hz (Option) frequency and is speed up its revolution till 100 Hz (Option) 2) Every EEV have 350 pulse (Option) [...]

20 Room Air Conditioner P ar t 2 Functions & Controls 5.6 P o wer Rela y Contr ol • Power relay turns on 1 second later after the power is supplied to the outdoor unit. • Control sequence : power on → PTC operating → power relay on 5.7 In verter 1. The single phase power AC is converted into DC. 2. The single phase power DC is converted[...]

Ser vice Manual 21 P ar t 2 Functions & Controls 5.8 Overheating Pr otection (P o wer Module) 5.8.1 9,12kBtu/h Model • If the temperature of the heat sink thermistor. reaches over Toff, the Compressor stop instantly. • The compressor operating frequency is limited according to the heat sink thermistor. (refer to below FIG.) • It will blin[...]

22 Room Air Conditioner P ar t 2 Functions & Controls 5.8.2 18,24,30kBtu/h Model • Function : Power module failure protection by checking the temperature of heat sink. There is a temperature sensor for checking the heat sink temperature. • Heat sink sensor failure error Short Check : if temperature ≥ 130°C(266 °F) Open Check : if temper[...]

Ser vice Manual 23 P ar t 2 Functions & Controls 5.9 T otal Current Control (Over Current Pr otection) 5.9.1 9,12kBtu/h Model 1) CT1 control • If the operating current reaches I1, the operating frequency of the compressor decreases. • After decreasing the operating frequency by 1step, if operating current is below I1 for 60 seconds continuo[...]

24 Room Air Conditioner P ar t 2 Functions & Controls 5.9.2 18,24,30kBtu/h Model 1) Detection : check the output DC voltage of Current Transformer(CT). 2) Current Transformer Sensing Error a) In initial power input, if the CT output is over 4.0V (25A) it shows. Error Code 40 (defect in CT sensing) 3) CT 1 detection : a) If total current exceeds[...]

Ser vice Manual 25 P ar t 2 Functions & Controls 5.10 DC P eak contr ol 5.10.1 DC P eak Current Error b y a fault signal of IPM • If the operating current of IPM reaches 35A 3A, the compressor stops instantly. • If DC PEAK occurs 5 times within 1 hour, the appliance turns off and displays Error Code 6(9,12kBtu/h Model) / Error Code 21(18,24[...]

26 Room Air Conditioner P ar t 2 Functions & Controls 5.11.2 In verter Compressor (18,24,30kBtu/h Model) 1) There can be two situations (a) Sensor is failed (Error Code 41) (b) Abnormal high temperature discharge temperature (error code for high discharge will be generated) Both cases unit will stop. 2) Compressor working (a) If discharge pipe [...]

Ser vice Manual 27 P ar t 2 Functions & Controls 5.11.3 Constant Compressor (only 30kBtu/h Model) 1) There can be two situations (a) Sensor is failed (Error Code 41) (b) Abnormal high temperature discharge temperature (error code for high discharge will be generated) Both cases unit will stop. 2) Compressor working (a) If discharge pipe tempera[...]

28 Room Air Conditioner P ar t 2 Functions & Controls 5.12 Low Ambient contr ol 5.12.1 9,12kBtu/h Model • If outdoor temperature drops below certain temperature, liquid back is prevented by reducing fan speed. • It can prevent frosting of evaporator and keep cooling operation • No matter even if the outdoor temperature reaches -10°C(14°[...]

Ser vice Manual 29 P ar t 2 Functions & Controls 5.14 Oil equalizing contr ol(30kBtu/h Model) Operating condition : 1) When the continuous inverter compressor running time at under 40 Hz(option) is over 2 hours(option) in 2 com- pressor system, oil restoring operation is made. 2) If compressor operating Hz is below 40 Hz by the safety control, [...]

30 Room Air Conditioner P ar t 3 T est Run 1. Check bef ore T est Run ...................................................................................................31 2. T est Run Flow chart .......................................................................................................32 3. T est Run Detail.............................[...]

Ser vice Manual 31 P ar t 3 T est Run Check to see whether there is any refrigerant leakage, and check whether the power or transmission cable is connected properly. Check whether the liquid pipe and gas pipe valves are fully opened. NOTE : Be sure to tighten caps. Confirm that 500 V megger shows 2.0 M Ω or more between power supply terminal bloc[...]

32 Room Air Conditioner Is cold air discharged for more than 3 minutes ? START Test operation for indoor unit Operation mode change to Heating mode Operate the unit in cooling mode. Does Test operation start? Refer to part4, 7 Electric part Yes No Yes Refer to part4, 5 Cycle part No Is hot air discharged ? After Hot Start NOTE: When outdoor tempera[...]

Ser vice Manual 33 P ar t 3 T est Run 1. Check that all tubing and wiring have been properly con- nected. 2. Check that the gas and liquid side service valves are fully open. Settlement of outdoor unit • Anchor the outdoor unit with a bolt and nut(ø10mm) tightly and horizontally on a concrete or rigid mount. • When installing on the wall, roof[...]

34 Room Air Conditioner P ar t 4 T r oub le Shooting 1. 2-W a y , 3-Wa y V alve ........................................................................................................3 5 2. Pumping Down ..............................................................................................................3 6 3. Evacuation (All amount of ref[...]

Ser vice Manual 35 P ar t 4 T rouble Shooting 2-way Valve (Liquid Side) 3-way Valve (Gas Side) Shaft position Shaft position Service port Closed Closed Closed (with valve cap) (with valve cap) (with cap) Open Closed Open (counter-clockwise) (clockwise) (push-pin or with vacumm pump) Open Open Closed (with valve cap) (with valve cap) (with cap) Clos[...]

36 Room Air Conditioner P ar t 4 T rouble Shooting • Procedure (1) Confirm that both the 2-way and 3-way valves are set to the open position. – 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. (2) Operate the unit for 10 to 15 minutes. (3 ) [...]

Ser vice Manual 37 P ar t 4 T rouble Shooting • Procedure (1) Connect the vacuum pump to the center hose of charge set center hose (2) Evacuation for approximately one hour. – Confirm that the gauge needle has moved toward 0.8 Torr. (3) Close the valve (Lo side) on the charge set, turn off the vacuum pump, and confirm that the gauge needle does[...]

38 Room Air Conditioner P ar t 4 T rouble Shooting Lo Charging cylinder Outdoor unit Indoor unit Liquid side Gas side Open 3-Way valve 3-Way valve OPEN Open Check valve (1) CLOSE Vacuum Gage • Procedure (1) Connect the charge hose to the charging cylinder. – Connect the charge hose which you dis-con- nected from the vacuum pump to the valve at [...]

Ser vice Manual 39 P ar t 4 T rouble Shooting T r ouble anal ysis 1. Check temperature difference between intake and discharge air, and operating current. All amount of refrigerant leaked out. Check refrigeration cycle. Refrigerant leakage Clog of refrigeration cycle Defective compressor Excessive amount of refrigerant Normal Temperature difference[...]

40 Room Air Conditioner P ar t 4 T rouble Shooting 2. Check temperature and pressure of refrigeration cycle. 1. The suction pressure is usually 8.5~9.5 kg/cm 2 . g at normal condition. 2. The temperature can be measured by attaching the thermometer to the low pressure tubing and wrap it with putty. NOTICE Suction pressure Temperature (Compared with[...]

Ser vice Manual 41 P ar t 4 T rouble Shooting The Product doesn ’ t operate at all. (9~30kBtu/h Model) Turn off the main power and wait until LED on outdoor PCB is off. Turn on the main power again. Does "Beeping" sound is made from the indoor unit? Does "Lighting" LED is mounted on the outdoor PCB? • Primarily, the operatin[...]

42 Room Air Conditioner P ar t 4 T rouble Shooting Turn on main power. While the compressor has been stopped, the compressor does not operate owing to the delaying function for 2 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 oper[...]

Ser vice Manual 43 P ar t 4 T rouble Shooting Turn on the main power. When in air circulation mode, compressor/outdoor fan is stopped. Turn off main power. Check the electrical wiring diagram of Outdoor side. Check the open or short of connecting wires between Indoor and Outdoor. Check the sensor for Indoor temperature is attatched as close as to b[...]

44 Room Air Conditioner P ar t 4 T rouble Shooting Turn on the main power. When in air circulation mode, compressor/outdoor fan is stopped. Turn off main power. Check the electrical wiring diagram of Outdoor side. Check the open or short of connecting wires between Indoor and Outdoor. Check the sensor for Indoor temperature is attatched as close as[...]

Ser vice Manual 45 P ar t 4 T rouble Shooting When indoor Fan does not operate.(9~30kBtu/h Model) T roub le 5 Check the SSR high speed operation by remote control. (the Indoor Fan Motor is connected) Turn off main power. Check the connection of CN-FAN. Check the Fan Motor. Check the Fuse(AC250V, T2A). Turn on the main power Check the related circui[...]

46 Room Air Conditioner P ar t 4 T rouble Shooting 7. Self-diagnosis Function ■ Error Indicator • The function is to self-diagnoisis airconditioner and express the troubles identifically if there is any trouble. • Error mark is ON/OFF for the operation LED of evaporator body in the same manner as the following table. • If more than two trou[...]

Ser vice Manual 47 P ar t 4 T rouble Shooting ■ 18,24,30kBtu/h Model Indoor Error 00 No Error ON 01 Indoor Room themistor error 1time OFF 02 Indoor in-piping sensor error 2times OFF 03 Remote controler error 3times OFF 04 Drain Pump error 4times OFF 05 Communcation error between in and out 5times OFF 06 Indoor Out-Piping sensor error 6times OFF 0[...]

48 Room Air Conditioner P ar t 4 T rouble Shooting Case of error LED02G (Green) LED01G (Red) Contents Error code CT Circuit malfunction Open / Short Open / Short Open / Short Open / Short Open / Short Over load combination Communication Poorly Check sum mismatching Cond. Temp. high Heat sink temp. high Open / Short CT Circuit (open/ short) D-pipe s[...]

Ser vice Manual 49 ■ T r oubleshooting Guide(9,12kBtu/h Model) P ar t 4 T rouble Shooting Description Cause of error 1 • Indoor TH. (sensor) is short or open • Indoor TH. (sensor) is not connected to the indoor pcb assembly • Damage or defect on the sensing circuit of indoor pcb assembly. (R01H, R02H, R03H, R04H, C01H, C02H) Indoor TH. is s[...]

50 Room Air Conditioner P ar t 4 T rouble Shooting 4 • Heat-sink TH. is damaged(short or open). • Heat-sink Temp. is over 95 ° C(203 ° F) • Damage or defect on the sensing circuit of outdoor pcb assembly. (R01H, R02H, C01H) Heat-sink Temp. is over 95 ° C(203 ° F) Heat-sink TH. is open or short Heat-sink TH. in INV-IC is Right ? Sensing ci[...]

Ser vice Manual 51 P ar t 4 T rouble Shooting 5 • Wrong or missing wiring between indoor and outdoor unit cable • Defect of communication components in indoor pcb assembly • Defect of communication components in outdoor pcb assembly • Defect of power supply components in outdoor pcb assembly • No ground connection in air conditioner unit [...]

52 Room Air Conditioner P ar t 4 T rouble Shooting Cause of error 6 • Supplied power is not normal • Comp Connector (CN-U,V,W) is disconnected or inserted to wrong position • Compressor is damaged (coil short) ➔ replace compressor • Too much Refrigerant • Defect in outdoor pcb assembly ➔ replace pcb assembly DC Peak Error Supplied vol[...]

Ser vice Manual 53 P ar t 4 T rouble Shooting 7 • Supplied power is not normal • Indoor/outdoor fan is locked • Too much refrigerant • Defect in current sensing circuit in outdoor pcb assembly Over current Error (CT2) Supplied voltage to Outdoor pcb is about AC 208~230V ? Does indoor / outdoor fan work normally ? YES No Check power source N[...]

54 Room Air Conditioner P ar t 4 T rouble Shooting 8 • Indoor fan is locked or separated • Fan connector is not connected to indoor pcb assembly • Defective in DC-fan driving circuit Indoor fan is locked (BLDC fan model only) Indoor fan is rotating ? (1) Indoor fan is rotating ? (2) YES No Check indoor unit - remove obstacles in indoor unit -[...]

Ser vice Manual 55 P ar t 4 T rouble Shooting 10 • D_pipe TH. is short or open • D_pipe TH. is not connected to the outdoor pcb assembly • Damage or defect on the sensing circuit of outdoor pcb assembly D-Pipe TH. is short or open D_PIPE TH. is connected to Outdoor pcb assembly ? D_PIPE TH. is right ? YES No Connect to CN-D_PIPE in outdoor pc[...]

56 Room Air Conditioner P ar t 4 T rouble Shooting 1) T roubleshooting CH01, CH02, CH06 Ω 10k Ω Check the resistance Check the voltage V 2.5VDC 01 02 06 Indoor air sensor Indoor inlet pipe sensor Indoor outlet pipe sensor • Open / Short • Soldered poorly • Internal circuit error • Open / Short • Soldered poorly • Internal circuit er[...]

Ser vice Manual 57 P ar t 4 T rouble Shooting 2) T roubleshooting CH05, CH53 05 / 53 Communication (Indoor → Outdoor) • Communication poorly • Power input AC 208~230V. (Outdoor, Indoor) • The connector for transmission is disconnected. • The connecting wires are misconnected. • The GND1,2 is not connected at main GND. • The communicat[...]

58 Room Air Conditioner P ar t 4 T rouble Shooting 3) T roubleshooting CH21 Ω Comp Copper pipe Resistance( Ω ) at 20°C(68°F) Resistance( Ω ) at 20 ° C(68 °F) 0.64 0.64 0.64 Inverter comp. V-W W-U U-V Terminal 0.8 0.8 0.8 Constant comp. 2M Ω 2M Ω 2M Ω Inverter comp. V-GND W-GND U-GND Terminal 2M Ω 2M Ω 2M Ω Constant comp. V U W[...]

Ser vice Manual 59 P ar t 4 T rouble Shooting 4) T roubleshooting CH21, CH22 V + - +- +- 21 22 Max. C/T C/T Internal circuit Over current (14A ) Initial current error Malfunction of compressor Blocking of pipe Low voltage input Refrigerant, pipe length, blocked, … Malfunction of current detection circuit. (Open / Short) The voltage of “C01N” [...]

60 Room Air Conditioner P ar t 4 T rouble Shooting 5) T roubleshooting CH23, CH28 V 23 28 DC Link Low voltage. DC Link High voltage • DC link volt. is 140VDC . • DC link volt. is 420VDC . • Check the power source. • Check the components. • Check the power source. • Check the components. Error code Title Cause of error Check point & [...]

Ser vice Manual 61 P ar t 4 T rouble Shooting 6) T roubleshooting CH24, CH25 CN TRNAS1 CN PRESS TRANS1 50Hz, DC12V 24 25 Press S/W Open Input voltage • Low / High press S/W open. • Abnormal Input voltage (140VAC , 300VAC ). • Check the connection of “CN_Press”. • Check the components. • Check the power source. • Check the components[...]

62 Room Air Conditioner P ar t 4 T rouble Shooting 7) T roubleshooting CH26, CH27 E C B E C B E C B 26 27 DC Compressor Position PSC Fault • Compressor position detect error • Over current at “IGBT” • Check the connection of comp wire “U,V,W” • Malfunction of compressor • Check the component of “IPM”, detection parts. • Chec[...]

Ser vice Manual 63 P ar t 4 T rouble Shooting 8) T roubleshooting CH32, CH33, CH40 LEV Openness (Pulse) COMP Frequency (Hz) Toff(105) ° C T1(90) ° C T2(95) ° C OFF Normal OFF Control Normal Normal Normal D-Pipe temp. (221) ° F (194) ° C (203) ° C 32 33 40 D-pipe (Inverter) temp. high (105°C(221°F) ) D-pipe (Constant) temp. high (105°C(221?[...]

64 Room Air Conditioner P ar t 4 T rouble Shooting 9) T roubleshooting CH41, CH44, CH45, CH46, CH47, CH65 Ω 41 44 45 46 47 65 D-pipe sensor (Inverter) Air sensor Condenser Pipe sensor Suction Pipe sensor D-pipe sensor (Constant) Heat sink sensor • Open / Short • Soldered poorly • Internal circuit error • Open / Short • Soldered poorly ?[...]

Ser vice Manual 65 P ar t 4 T rouble Shooting 10) T roubleshooting CH51, CH60 51 60 Over capacity EEPROM Check sum • Over capacity Combination • Check sum error • Check the indoor unit capacity. • Check the combination table. • Check the PCB ASM P/No. • Check the poor soldering. Display code Title Cause of error Check point & Normal[...]

66 Room Air Conditioner P ar t 4 T rouble Shooting 11) T roubleshooting CH61, CH62 61 62 Condenser pipe sensor temp. high Heat sink sensor temp. high • Condenser pipe sensor detected high temp.(65°C(149°F)) • Heat sink sensor detected high temp.(85°C(185°F)) • Check the load condition. • Check the sensor of Condenser pipe sensor. • Ch[...]

P/NO : MFL41161601 AUGUST, 2007[...]