Download Single Packaged Air Conditioner SERVICE MANUAL
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Single Packaged Air Conditioner SERVICE MANUAL MODEL: EK-H2408C00 Air Conditioner Service Manual TABLE OF CONTENTS Safety Precautions ............................................................................................................................3 Model Number Nomenclature ................................................................................................. 8 General Data ............................................................................................................................. 9 Dimensions ............................................................................................................................. 10 Refrigerant Circuit diagram....................................................................................................11 Wiring Diagram....................................................................................................................... 12 Trouble Shooting Guide......................................................................................................... 13 Electric Parts Trouble Shooting Guide................................................................................. 17 Feature of Controller............................................................................................................. 24 Exploded View and Replacement Parts List........................................................................ 30 2 Single Packaged Air Conditioner Safety Precautions Safety Precautions To prevent injury to the user or other people and property damage, the following instructions must be followed. ■ Be sure to read before installing the air conditioner. ■ Be sure to observe the cautions specified here as they include important items related to safety. ■ Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications. WARNING This symbol indicates the possibility of death or serious injury. CAUTION This symbol indicates the possibility of injury or damage to properties only. ■ Meanings of symbols used in this manual are as shown below. Be sure not to do. Be sure to follow the instruction. WARNING ■ Installation Do not use a defective or underrated circuit breaker. Use this appliance on a dedicated circuit. For electrical work, contact the dealer, seller, a qualified electrician, or an Authorized Service Center. Always ground the product. • There is risk of fire or electric shock. • Do not disassemble or repair the product. There is risk of fire or electric shock. • There is risk of fire or electric shock. Install the panel and the cover of control box securely. Always install a dedicated circuit and breaker. Use the correctly rated breaker or fuse. • There is risk of fire or electric shock. • Improper wiring or installation may cause fire or electric shock • There is risk of fire or electric shock. Service Manual 3 Safety Precautions Use the specified wires to connect the unit. Do not install, remove, or reinstall the unit by yourself (customer). Be cautious when unpacking and installing the product. • There is risk of fire or electric shock. • There is risk of fire, electric shock, explosion, or injury. • Sharp edges could cause injury. Be especially careful of the case edges and the fins on the condenser and evaporator. For installation, always contact the dealer or an Authorized Service Center. Do not install the product on a defective installation stand. Be sure the installation area does not deteriorate with age. • There is risk of fire, electric shock, explosion, or injury. • It may cause injury, accident, or damage to the product. • If the base collapses, the air conditioner could fall with it, causing property damage, product failure, and personal injury. ■ Operation Do not let the air conditioner run for a long time when the humidity is very high and a door or a window is left open. Take care to ensure that power cable could not be pulled out or damaged during operation. Do not place anything on the power cable. • Moisture may condense and wet or damage furniture. • There is risk of fire or electric shock. • There is risk of fire or electric shock. Do not plug or unplug the power supply plug during operation. Do not touch(operate) the product with wet hands. Do not place a heater or other appliances near the power cable. • There is risk of fire or electric shock. • There is risk of fire or electrical shock. • There is risk of fire and electric shock. 4 Single Packaged Air Conditioner Safety Precautions Do not allow water to run into electric parts. Do not store or use flammable gas or combustibles near the product. Do not use the product in a tightly closed space for a long time. • It may cause There is risk of fire, failure of the product, or electric shock. • There is risk of fire or failure of product. • Oxygen deficiency could occur. Gasolin When flammable gas leaks, turn off the gas and open a window for ventilation before turn the product on. If strange sounds, or small or smoke comes from product. Turn the breaker off or disconnect the power supply cable. Stop operation and close the window in storm or hurricane. If possible, remove the product from the window before the hurricane arrives. • Do not use the telephone or turn switches on or off. There is risk of • There is risk of electric shock or fire. • There is risk of property damage, failure of product, or electric shock. When the product is soaked (flooded or submerged), contact an Authorized Service Center. Be cautious that water could not enter the product. explosion or fire Do not open the panel of the product during operation. (Do not touch the electrostatic filter, if the unit is so equipped.) • There is risk of physical injury, electric shock, or product failure. • There is risk of fire or electric shock. • There is risk of fire, electric shock, or product damage. Ventilate the product from time to time when operating it together with a stove, etc. Turn the main power off when cleaning or maintaining the product. • There is risk of fire or electric shock. • There is risk of electric shock. Service Manual 5 Safety Precautions When the product is not be used for a long time, disconnect the power supply plug or turn off the breaker. Take care to ensure that nobody could step on or fall onto the unit. • There is risk of product damage or failure, or unintended operation. • This could result in personal injury and product damage. CAUTION ■ Installation Always check for gas (refrigerant) pressure after installation or repair of product. Install the drain hose to ensure that water is drained away properly. Keep level even when installing the product. • Low refrigerant levels may cause failure of product. • A bad connection may cause water leakage. • To avoid vibration or water leakage. 90° Do not install the product where the noise or hot air from the outdoor unit could damage the neighborhoods. Don't use people to lift and transport the product. Do not install the product where it will be exposed to sea wind (salt spray) directly. • It may cause a problem for your neighbors. • Avoid personal injury. • It may cause corrosion on the product. Corrosion, particularly on the condenser and evaporator fins, could cause product malfunction or inefficient operation. Having perfect vacuum process in the factory, our units don't have drier but have filter in the refrigerant circuit. In case of recharging R-410A gas in the field, "DRIER" must be installed on the liquid line which is connected from discharge part of condenser to intake part of evaporator. Because the refrigerant circuit is capable of containing water with imperfect vacuum. 6 Single Packaged Air Conditioner Safety Precautions ■ Operation Do not expose the skin directly to cool air for long periods of time. (Don't sit in the draft.) Do not use the product for special purposes, such as preserving foods, works of art, etc. It is a consumer air conditioner, not a precision refrigeration system. • This could harm to your health. • There is risk of damage or loss of property. Do not block the inlet or outlet of air flow. Use a soft cloth to clean. Do not use harsh detergents, solvents, etc. Do not touch the metal parts of the product when removing the air filter. They are very sharp! • It may cause product failure. • There is risk of fire, electric shock, or damage to the plastic parts of the product. • There is risk of personal injury. x Wa Thinner Do not step on or put anything on the product. (outdoor units) Always insert the filter securely. Clean the filter every four weeks or more often if necessary. Do not insert hands or other objects through the air inlet or outlet while the product is operated. • There is risk of personal injury and failure of product. • A dirty filter reduces the efficiency of the air conditioner and could cause product malfunction or damage. • There are sharp and moving parts that could cause personal injury. Do not drink the water drained from the product. Use a firm stool or ladder when cleaning or maintaining the product. • It is not sanitary and could cause serious health issues. • Be careful and avoid personal injury. Service Manual 7 Model Number Nomenclature Model Number Nomenclature EK-H2408C00 1 2 3 4 5 6 7 8 1 Manufacturing plant/Refrigerant 2 Classification 3 Type 4 Capacity(Btu/h) 5 Voltage/frequency/phase 6 Air flow/Top Side 7 Method/SEER 8 Development Sequence 8 Single Packaged Air Conditioner A Changwon/R-410A E Turkey/R410A K Turkey/R-22 L Changwon/R-22 K Single packed Air Conditioner N Ducted split Air Conditioner C Cooling Only H Heat pump 036(36000 Btu/h)~360(360000Btu/h) 8 380~415V, 50Hz, 3Phase 9 380V, 60Hz, ,3Phase B 220V, 60Hz, 3Phase D 440~460V, 60Hz, 3Phase C Convertible Air Flow(Down+Horizontal) H Horizontal Air Flow 0 MICOM Control/10 A Mechanic Control/10 D Mechanic Control/13 Given Number by Delevelopment Sequence General Data General Data Nominal ton Models Capacity (Ton) Cooling Capacity (net) Heating Capacity (net) Electrical Data Voltage M.C.A (with standard motor) Cooling/Heating Power Input Cooling/Heating Performance Air Circulation Nominal CFM EER (SEER) Cooling/Heating Sound Rating Feature Wired Remote Controller Time Delay Safety Function Cooling Operation Mode Heating Operation Mode (with E/Heater) Soft Dry Operation Timer setting (24-Hour on/off) Auto Restart Mode Humidifier Funtion Test Function Defrost Hot Start Self-Diagnosis Function Phase Reversal Error Sensing Phase Loss Sensing Filter Type Compressor Type Quantity Outdoor Coil Type Tube Size (O.D) Row/FPI Length Face area Indoor Coil Type Tube Size (O.D) Row/FPI Length Face area Type No. Used/Diameter (in.) Drive Type CFM No. Motor / Motor Output (Hp) Motor RPM Indoor Fan Type No. Used Diameter / Width Drive Type / Motor Step No. Motors Motor Output (standard / oversized) Motor rpm (standard / oversized) Drain Connection Size (in.) Dimensions (WxHxD) (Btu/hr) (W) (Kcal/h) (Btu/hr) (W) (Kcal/h) (V,PH) (Amps) (Watt) CFM (Btu/hr.W) Bell (inch) (mm) (inch) (mm) (sq.ft) (m2) (inch) (mm) (inch) (mm) (sq.ft) (m2) Outdoor Fan Net Weight inch/inch hp/hp hp/hp (inch) (mm) (kg) (lbs) 1) Test Condition of ISO Rated Cooling Capacity & Heating Capacity: - Cooling : Ambient 95°F, Air Entering Temperature : 80.6°F DB and 6.2°F WB - Heating : Ambient 44.8°F, Air Entering Temperature : 68°F DB and 59°F WB 20 EK-H2408C00 225,000 65,941 56,699 250,000 73,268 62,999 380~415V , 3PH 70 26,500/27,800 7,500 8.5/9.0 9.2 O O O O O O O O O O O O O O Washable & Anti-Fungus Scroll 4 High Efficiency 9/32 7 3R / 17 FPI 78 3/4 2,000 41.59 3.86 High Efficiency 3/8 9.52 3R / 16 FPI 39 3/8 1,000 14.22 1.32 Propeller 4EA / 22 Direct 12,500 4 / 0.4 950 Centrifugal Blower Fan 1 EA 18" / 18" Belt / 1 1EA 5 Hp / 7.5 Hp 2,870~2,900 / 2,860~2,900 1 114 3/32*49 7/82*86 5/8 2,898*1,250*2,200 900 1,984 2) Filters are standard supply. Service Manual 9 Dimensions Dimensions UNIT Dimensions (Figure 1A) Unit: inch(mm) UNITS 20RT H 49 7/32 (1250) I 86 5/8 (2200) J 114 3/32 (2898) K 7 3/32 (180) L 48 13/32 (1230) M 3 5/32 (80) N 3 5/32 (80) CLEARANCE 34" CLEARANCE 16" K H N M J I CLEARANCE 34" L CLEARANCE 46" Figure 1A HORIZONTAL FLOW APPLICATION (Figure 1B) Unit: inch(mm) UNITS 20RT A 34 5/8 (880) B 17 5/8 (448) C 23 5/8 (600) D 3 31/32 (101) E 7 5/32 (182) F 39 3/8 (1000) G 5 1/8 (137.5) CLEARANCE 34" CLEARANCE 16" F E D C B CLEARANCE 46" G 25 19/32 (650) Figure 1B DOWN FLOW APPLICATION (Figure 1C) 20RT UNITS A 23 B 15 5/8 (396) C 34 5/8 (880) D 6 11/16 (170) E 6 4/8 (165) F 39 3/8 (1000) G 6 11/16 (170) H 25 19/23 (650) 5/8 (600) 10 Single Packaged Air Conditioner B C D G E A F Unit: inch(mm) CLEARANCE 34" A RETURN SUPPLY TOP VIEW H H H Figure 1C Refrigerant Circuit Diagram Refrigerant Circuit Diagram OUTDOOR COIL 3.36(I.D)*23EA CAPILLARY TUBE 2.0(I.D)*1EA PRESSURE CHECK PORT PRESSURE CHECK PORT INDOOR COIL CAPILLARY TUBE 1.8(I.D)*9EA HI PRESSURE SWTICH Cooling CHECK VALVE COMP A-1 CAPILLARY TUBE 2.0(I.D)*3EA ACCUM Heating CHECK VALVE LOW PRESSURE SWTICH COMP A-2 CHECK VALVE CAPILLARY TUBE 1.8(I.D)*9EA CAPILLARY TUBE 2.0(I.D)*1EA PRESSURE CHECK PORT PRESSURE CHECK PORT HI PRESSURE SWTICH CAPILLARY TUBE 2.0(I.D)*3EA CHECK VALVE 3.36(I.D)*23EA Cooling CHECK VALVE COMP A-1 ACCUM Heating CHECK VALVE COMP A-2 LOW PRESSURE SWTICH : Refrigerant Flow Service Manual 11 Wiring Diagram Wiring Diagram EK-H2408C00 3854U20290U 54 003399 19 Rev:a 12 Single Packaged Air Conditioner Troubleshooting Guide Troubleshooting Guide PACKAGE AIR CONDITIONER VOLTAGE LIMITS NAME PLATE RATING MINIMUM MAXIMUM 380~415V 342V 457V 1. No cooling and heating operation performed 1) Both the blower and the compressor do not work WHAT TROUBLED Other parts except the unit COMPLAINTS HOW TO CHECK REMEDY • Electric supply interrupted • Defective power wiring • Cut off power fuse Measure power sypply with a tester in case that the same power source is supplied to other equipment except the unit, what and where troubled can be discovered by checking the operation of other equipment. Too low voltage Measure it with a tester. Check the power source. Use a thick cable if necessary. Magnetic Contactor for compressor & fan motor Control point is on condition of "OFF" due to trouble. Make short-circuit, then measure it with tester. Replace it if necessary. Operating switch Troubled or defective contactor Check it with the eyes or tester. Repair or replace it. • Repair a switch box and relative instrument. • Replacement of fuse • Request a power supplier to repair. 2) Only Indoor blowers do not work WHAT TROUBLED Motor Electric wiring COMPLAINTS • Over heated • Wiring short • Cut- OFF of wiring • Short circuited on operation HOW TO CHECK REMEDY Check it with tester Repair or replace it. Check it with a tester. Rewiring or Repair. Service Manual 13 Troubleshooting Guide 3) Only outdoor fan does not work WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY Motor • Over-heated • Wire short Check how it is insulated. Repair or replace it. Electric Wiring Cut off of wiring Check it with a tester. Rewiring or repair. Short circuited on operation Capacitor Defected Check it with tester. Replace it. 4) Only compressor does not work WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY Magnetic switch for compressor motor Defective contact, magnetic coil troubled. Check it with the eyes on with a tester. Repair or replace it. Compressor motor Troubled over-heated (layer short) Check how it is insulated. Replace or repair the compressor. High pressure switch Troubled or defective contact or operating Check it with a tester. Replace it if necessary. Electric circuit Defective connection or disconnection of the circuit for compressor. Check it with a tester. Rewiring or push reset button. 14 Single Packaged Air Conditioner Troubleshooting Guide 2. The Units discontinue after the operation started WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY Outdoor coil Coil is dirty *1 Checking Wash it by means of something like chemical washing. In-condensable gas blended. Air intruded into the refrigerant pipe line *1 In the event that difference between the saturating temperature corresponding to high pressure and the temperature of air discharged from the outdoor coil is more than 15°C, incondensable gas may be blended. Extract air by vacuum pump, then replenish (charge) the refrigerant. Improper adjustment Check it with a pressure gauge. Read just it to normal operating pressure. (Note) Don't alternate the specified adjusting pressure. If the adjusted pressure exceed the specified range, it will cause a great accident. A shortage of refrigerant amount. * 2 Check pressure Replenish the refrigerant. Repair the spot where it is leaked. Reverse rotation of fan Obstacle Confirm the wind blowing out upward. Air short circuit *1 Check it with eyes. If reversed, connect interchanged wires to each terminal. Power wirings. High pressure switch Refrigerant Outdoor Fan Note: Use an appropriate measuring instrument for readjustment. *1: High-pressure switch moves. *2: Low- pressure switch moves. Service Manual 15 Troubleshooting Guide 3. The unit is working, but not cooling and heating sufficiently (Both blower and compressor are working) WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY Load Much Cooling or Heating load Heat load increased. Window or door has many cracks or gaps. Do necessary disposal respectively. Air flow Obstacle disturbs Intake of uniform airflow. Checking Correct it. Short air volume Reverse rotation of blower. Checking Correct it. Refrigerant Shortage in the charged refrigerant. Coil inlet pipe is frosted Recharge it. (Repair the leakage spot). Air passage Improper or foreign bodies Checking Correct or clear the foreign bodies. Air filter Clogged with dust Checking Cleaning 4. All the functions are performed as specified, but very noisy and vibrant WHAT TROUBLED Compressor Blower COMPLAINTS HOW TO CHECK REMEDY Liquid refrigerant flooding back from the evaporator. • Check for refrigerant over-charge. • Check to see if the intake air temperature is extremely cold. • Check for insufficient air flow quantity. Faulty Discharge valve and suction valve. • Checking • Replace the compressor Fan broken. Checking Repair or replace it. Clear the foreign bodies. Foreign matters intruded. Screws Looseness or fail-off of screws Checking Correct Electric troubles (Magnetic contactor) Defective contact. Defective contact point. Rusting and foreign matters in the iron core contact face. Defective contact of the operating switch. Checking Repair and clean or replace it. Others Improper installation Checking Correct it. 16 Single Packaged Air Conditioner Electronic parts Troubleshooting Guide Electronic parts Troubleshooting Guide Possible trouble 1 Is the input voltage of Main PCB AC220V? : The unit does not operate. NO 1. Check the Fuse. 2. Check the wiring of AC220V. YES Is the output voltage of IC03D(7812 ) on the main PCB DC5V? NO 1. Exchange IC03D(7805) on the main PCB. YES Is the output voltage of IC01A(7036) on the main PCB DC5V? NO 1. Exchange IC01A(7036) on the main PCB. YES OSC01B vibration? NO 1. Exchange OSC01B. 2. Check the pattern around OSC01B on the main PCB. YES 1. Exchange main PCB ASS'Y Possible trouble 2 Is the power ON? : The remote-controller does not operate. NO 1. Check the FUSE. 2. Check the input voltage of Main PCB ASS'Y. YES Is the input voltage of remote-controller DC12V? YES NO 1. Check or exchange the IC03D on the Main PCB. 2. Check or exchange the Connector (RED, BROWN) of the remote controller. 1. Exchange remote-controller 2. Check or exchange the Main PCB ASS'Y. Service Manual 17 Electronic parts Troubleshooting Guide Possible trouble 3 : Key input of remote-controller does not respond. Is the connection between MAIN PCB and remote-controller correct? NO 1. Check or repair Connector wiring. 2. Exchange the Connector. YES Is any key on the remote-controller keeping pressed? YES 1. Replace the pressed key. 2. Exchange the Knob or Key. YES 1. Remove cause of Check. NO Is there Check(F**) on the remote controller LCD? NO Is the input power voltage of remote-controller DC12V? NO 1. Check 220V Power on the MAIN PCB. YES Is there OSC01B vibration on the remote-controller PCB? NO 1. Exchange OSC01B 2. Check the pattern around OSC01B on the remote-controller PCB. YES Do Keys have troubles? YES 1. Check Keys. 2. Repair or exchange Key. NO Exchange remote-controller. Possible trouble 4 Are there trouble in LCD parts? : LCD display on the remote-controller shows some trouble. YES 1. Check crack, damage of LCD. 2. Check LCD pattern. NO Is there trouble in the remote-controller PCB ASS'Y? YES NO Exchange remote-controller. 18 Single Packaged Air Conditioner 1. Check or repair all IC with dust or moisture on the PCB. 2. Exchange remote-controller PCB. Electronic parts Troubleshooting Guide Possible trouble 5 Is the unit operating? : No cooling operation performed. NO 1. Press power ON/OFF button. YES Is the cooling mode? NO 1. Press cooling operation key. 2. After reenergizing power supply, press power "ON/OFF" button. NO 1. Set following. 'Set Temp. < Room Temp.' YES Set Temp. < Room Temp.? YES Is the output voltage of IC03D on the MAIN PCB DC5V? NO 1. Check or exchange IC03D on the MAIN PCB. YES Is the output voltage of IC01M's 11,12(COMP B)PIN on the MAIN PCB DC0V? NO 1. Check or exchange IC01M. 2. Check 3-minutes time delay. YES Is the voltage between A/B(COMP B) of CN-COMP and NEUTRAL 220V? NO 1. Check or exchange RY4/RY5(COMP B). YES Is the magnetic contactor for compressor ON? NO 1. Check the wiring of Magnetic contactor. 2. Exchange Magnetic contactor. YES 1. Check Compressor and Capacitor for Compressor. NOTE: 3ø model has not capacitor for compressor. Service Manual 19 Electronic parts Troubleshooting Guide Possible trouble 6 Is the heater operation? : No heater operation performed. NO 1. Select heater operation mode. YES Is the heater LCD "ON"? NO 1. Reconnecting power supply. Press Heater Key. NO 1. Set following. 'Set temp. > Room temp.' YES Set temp. > Room temp.? YES Is the output voltage of IC03D on the MAIN PCB DC5V? NO 1. Check or exchange IC03D, IC02D on the MAIN PCB. YES Is the output voltage of IC02M's 15, 16PIN on the MAIN PCB 0V? NO 1. Check or exchange IC02M. YES Is the voltage between A/B(Heat B) of CN-HEAT and NEUTRAL 220V? NO 1. Check or exchange RY13/RY14(Heat A, B). YES Is the magnetic contactor for heater ON? NO YES Check or exchange E/Heater. 20 Single Packaged Air Conditioner 1. Check the wiring of Magnetic contactor. 2. Exchange Magnetic contactor. Electronic parts Troubleshooting Guide Possible trouble 7 Is the indoor fan operation? : No humidifier operation performed. NO 1. Press cooling or fan operation or heater operation key. YES Is the HUMID LCD "ON"? NO 1. Press humidifier Key. YES Is the output voltage of IC03D on the MAIN PCB DC5V? NO 1. Check or exchange IC03D. IC02D on the MAIN PCB. YES Is the output voltage of IC01M's 10PIN on the MAIN PCB 0V? NO 1. Check or exchange IC01M. YES Is the voltage between 1PIN of CN-HUMID and NEUTRAL 220V? NO 1. Check or exchange RY3. YES Is the magnetic contactor for humidifier ON? NO 1. Check the wiring or Magnetic contactor. 2. Exchange Magnetic contactor. YES Check the humidifier. Service Manual 21 Electronic parts Troubleshooting Guide Possible trouble 8 Is the unit operating? : Indoor motor does not operate. NO 1. Press power ON/OFF button. 2. Reconnect the power supply. YES Is the output voltage of IC02M's 14PIN on the MAIN PCB 0V? NO 1. Check or exchange IC01M. YES Is the voltage between 1PIN(IN) of CN-FAN(IN) and NEUTRAL 220V? NO 1. Check or exchange RY10. YES Is the "Power relay" for indoor motor ON? NO 1. Check the wiring of "Power relay". 2. Exchange "Power relay". YES Check the indoor motor. Possible trouble 9 Is it cooling operation? : Outdoor motor does not operate. NO 1. Press power "ON/OFF" button. 2. Select cooling operation. YES Is the compressor operating? NO YES Is the output voltage of IC02M's 13/12(OUT FAN B) on the MAIN PCB 0V? NO 1. Set following. Set temp. < Room temp. 2. Wait, if the unit has operating with 3-minute time delay. 1. Check or exchange IC02M. YES Is the voltage between OUT A/B of CN-FAN and NEUTRAL 220V? NO 1. Check or exchange RY11/RY12(OUT FAN B). YES Is the "Power relay" for outdoor motor ON? NO YES Check the outdoor motor A/B. 22 Single Packaged Air Conditioner 1. Check the wiring of "Power relay". 2. Exchange "Power relay". Electronic parts Troubleshooting Guide Possible trouble 10 Is the heater operation? : No heater operation performed. NO 1. Select heater operation mode. YES Is the heater LCD "ON"? NO 1. Reconnecting power supply. Press Heater Key. NO 1. Set following. 'Set temp. > Room temp.' YES Set temp. > Room temp.? YES Is the output voltage of IC03D on the MAIN PCB DC5V? NO 1. Check or exchange IC03D on the MAIN PCB. YES Is the output voltage of IC01M's 16PIN on the MAIN PCB 0V? NO 1. Check or exchange IC01M. YES Is the voltage between 1PIN of CN5 and NEUTRAL 220V? NO 1. Check or exchange RY1. YES Is the magnetic contactor for heater OK? NO 1. Check the wiring of Magnetic contactor. 2. Exchange Magnetic contactor. YES Check or exchange E/Heater. Service Manual 23 Features of Controller Features of Controller 1. Main Controller Circuit Diagram 24 Single Packaged Air Conditioner (L) (N) FUSE RY13 HEAT(A) IN FAN(IN) B HEAT(B) A CN_HAETER R17K D11K A R08K D06D IC02K CN_FAN FAN_OUT (B) B D07D FAN_OUT (A) IC03K R IC01K IC01D S/TRANS RY3 HYMID IC02D C03D C09D ZD02D CN_HUMID COMP(B) C03D1 L01D COMP(A) 4WAY(B) CN_COMP D03D COMP(B) C01J R03D T S C05D OUT BP(B) 4WAY(A) CN_BYPASS IN JP03 JP06 JP05 JP04 BP(A) RY6 ZNR01J CN_POWER JP07 BP(B) CN_B_CYCLE JP02 C07D OUT IN JP10 JP09 JP08 CN_A_CYCLE BP(A) JP12 PWB:6870A20012A ASM:6871A10041 1 CN_RETURN_AIR CN_SUB 3 CN_THMO 1 2 CN_TEMP_OUT 60 5 D02D 55 10 R11D 50 15 NF01J RY14 4 JP18 JP17 SWITCH JP14 L02K D09K CN_CC (B) (A) CN_H/P (WH) TEST_SW 45 20 LED4 LED3 LED2 LED1 40 25 NTC01D RY4 R18K RY10 D08D C02A L01K JP15 35 30 C01D RY11 (B) (A) CN_REMO OSC01B D01D RY5 CN_PHASE RY12 COMP(A) RY9 JP11 MICOM JP01 4WAY(A) RY8 4WAY(B) RY7 CN_ZONE IC01A D30CI D11D Features of Controller 2. Feature of Main Controller ZD01F Service Manual 25 CN_L/P(YL) OP_J1 Features of Controller 3. Feature of Remote-Controller PCB ASS'Y 4. Feature of Remote-Controller LCD AUTO SWING OPERATION SET TEMP Room Temp HI MED LO AUTO Heater Preheat JET Defrost Humidify Filter Out door ZONE 1 2 3 4 Time Timer Operation unit On Off Set no. Time 01 03 SUB FUNCTION Program set 05 26 Single Packaged Air Conditioner 07 09 11 13 15 17 19 21 23 Features of Controller 5. Error Mode & Corrective Method Error mode Cause of error Sensing condition of error CH01 OPEN/SHORT of Voltage of sensing: Over 4.8V room temp. Voltage of sensing: Less than sensor 0.5V CH02 OPEN/SHORT of Voltage of sensing: Over 4.8V indoor pipe temp. Voltage of sensing: Less than 0.5V sensor Communication Error Method of SVC Remark Room 1. Check the voltage of "CO1H" temp.(25°C) on the remote controller. = DC 2.5V 2. Check the temp. sensor of remtote controller. 1. Check the voltage between PIN 3 Pipe temp.(25°C) and 4 of CN-A cycle/CN-B cycle. = DC 2.2V 2. Check the temp. sensor of indoor pipe. CH03 Communication interruption between remote controller and Main PCB for 3 minutes. 1. Check the connecting wire between main PCB remote controller. 2. Check the input voltage of remote-controller. 3. Check the wiring of remote-controller. Input voltage of remote-controller = DC 12V CH04 OPEN/SHORT of Voltage of sensing: Over 4.8V Voltage of sensing: Less than outdoor pipe 0.5V sensor 1. Check the voltage between PIN 1 and 2 of CN-A cycle/CN-B cycle ON the main PCB. 2. Check the temp. sensor of remtote controller. Pipe temp.(25°C) = DC 2.5V CH05 OPEN/SHORT of Voltage of sensing: Over 4.8V Voltage of sensing: Less than outdoor room 0.5V temp. sensor 1. Check the voltage between PIN 1 and 3 of CN-TEMP OUT on the main PCB. 2. Check the temp. sensor of outdoor room. Room temp.(25°C) = DC 2.2V CH16 OPEN of A_Cycle_Low Pressure Switch 1. Check Low Pressure Switch 2. Check Refrigerant pressure CH17 OPEN of B_Cycle_Low Pressure Switch Sensing the numer of Low pressure S/W open after power_On • First time within 1 minute - 3 times during 30 minutes after first time sensing - 6 times until 30 minutes after first time sensing CH18 OPEN of A_Cycle_High Pressure Switch 1. Check High Pressure Switch 2. Check Refrigerant pressure CH19 OPEN of B_Cycle_High Pressure Switch Sensing the numer of high pressure S/W open after power_On • First time within 1 minute - 3 times during 30 minutes after first time sensing - 6 times until 30 minutes after first time sensing CH21 Phase Reversal Error Sensing the Reversal Phase 1. Check Power Connection CH22 Phase Loss Sensing the Phase Missing 1. Check Power Connection 1. Check Low Pressure Switch 2. Check Refrigerant pressure 1. Check High Pressure Switch 2. Check Refrigerant pressure Service Manual 27 F eatures of Controller 6. Principal part list of controller Return Air Outdoor Sensor Room Sensor Remark 6323AQ3214M EK-H2408C00 6871A10041H 6711A20043B EBG30413001 EBG30413002 (OPTIONAL) 6323A20010A LG No Heat Pump Model Main PCB ASM EK-H2408C00 ARCELIK-LG No 5400296908 Remote controller Pipe Sensor Pipe Sensor A(In/Out) B(In/Out) 5400305202 5400390201 5400390202 5400298512 (OPTIONAL) 5400403001 7. Principal partlist of Main PCB ASM No 1 2 3 4 5 6 Part No LG EAN30788301 6920WRD008A 6920AQ9054F 6212A90001E 6900AQ9028N 6102AQ9075A Part No ARCELIK-LG 5400403601 5400403701 5400061906 5400314805 5400061413 5400057601 Part Name MICOM(MAIN) RELAY RELAY RESONATOR FUSE VARISTOR Remarks H/P RY3,4,5,10,11,13,14 RY1,2,8,9,12 8. Principal partlist of Remote Controller No 1 2 3 4 Part No LG OITO641010B 6304A30001C 6871A20043A 6871A20043H Part No ARCELIK-LG 5400403801 5400315003 5400403901 5400403908 Part Name MICOM(Remote Controller) LCD Remote C PCB ASM Remote C PCB ASM 28 Single Packaged Air Conditioner Remarks MICOM Cooling Only Heat Pump Heat Pump Features of Controller 9. Explanation of principal function ■ Flow Chart START(Power supply) YES 1. Initialize "micom". 2. A/D convert. 3. Main PCB: Waiting cooling operation. 4. Remote controller: Waiting input. Dehumidification Mode? A NO Heater operation mode? YES YES Power ON? YES NO Dehumidification operating NO Set Temp. > Indoor Temp. YES YES NO Cooling Mode? Stop condition? Heater operating YES YES Go to A NO Set Temp. < Indoor Temp. YES NO YES Stop condition? YES YES Go to A Time delay mode NO Fan only operating Cooling operating NO Stop condition? YES Go to A NO Stop condition? YES Go to A Service Manual 29 Exploded View and Replacement Parts List Exploded View and Replacement Parts List • Exploded View 237204-2 435312 237204-1 437212 137213-1 554160 552202 548490 566000-2 559010 552201 566000-1 561410 263230 561410 354210 552111-2 546810 552111-1 554031 137210-2 549610 552111-3 137210-1 330870 359012 342800 349600 346810 W4400 145610 145610 152302 237204-1 237204-2 263230 268714 566001-1 137213-2 137213-3 566001-2 W6920 W0CZZ 249950 267110 30 Single Packaged Air Conditioner Exploded View and Replacement Parts List •Replacement Parts List LOCATION No 145610-1 145610-2 152302 249950 263230 263230 263230 267110 268714 330870 342800 346810 349600 354210 359012 435312 437212 546810 548490 549610 552111-1 552111-2 552201 554031 554160 559010 566000-1 566000-2 566001-1 566001-2 137210-1 137210-2 137213-1 137213-2 137213-3 237204-1 237204-2 W0CZZ W4400 W6920 552202 561410 552111-3 DESCRIPTION PULLEY ASSEMBLY PULLEY ASSEMBLY FILTER(MECH),A/C CONTROL BOX ASSEMBLY, SINGLE THERMISTOR ASSEMBLY THERMISTOR ASSEMBLY THERMISTOR ASSEMBLY REMOTE CONTROL ASSEMBLY PWB(PCB) ASSEMBLY, MAIN DRAIN PAN ASSEMBLY BEARING MOTOR ASSEMBLY, INDOOR BRACKET ASSEMBLY EVAPORATOR ASSEMBLY, FIRST FAN ASSEMBLY, BLOWER GRILLE ASSEMBLY, DISCHARGE (OUTDOOR) PANEL REAR(OUTDOOR) MOTOR ASSEMBLY, OUTDOOR ACCUMULATOR ASSEMBLY (MECH) MOUNT ASSEMBLY, MOTOR (OUTDOOR) TUBE ASSEMBLY, CAPILLARY TUBE ASSEMBLY, CAPILLARY VALVE, CHECK CONDENSER ASSEMBLY, FIRST COMPRESSOR FAN ASSEMBLY , PROPELLER SWITCH, PRESSURE SWITCH, PRESSURE SWITCH, MAGNET SWITCH, MAGNET PANEL ASSEMBLY, FRONT(INDOOR) PANEL ASSEMBLY, FRONT(INDOOR) PANEL ASSEMBLY, SIDE PANEL ASSEMBLY, SIDE PANEL ASSEMBLY, SIDE PANEL, SIDE PANEL, SIDE CAPACITOR, DRAWING BELT, V RELAY VALVE,REVERSING COIL ASSEMBLY,REVERSING VALVE B CAPI ASSY LG PART No. ARCELIK-LG PART No. EK-H2408C00 3A00217S 4561A30003E 5230A20003Q 4995A10092F EBG30413001 EBG30413002 6323A20010A 6711A20043B 6871A10041H 3087A10013C 4A00131B 4681A20093D 4811A10001A 5421A20151A 5835A20003D 3530A20007H 3720A10249B 4681A20106E 4848A20001J 4961A20029A 5211A10549A 5211A10549B 3A01020L 5403A20137S 2520UBDY2AB 5901A10010A 3A02524H 3A02524L 6600B000032 6600B000041 3721A10073B 3721A10074B 3721A10075D 3721A10076C 3721A10076D 3720A13001C 3720A13001D 2A00986C 4400A30002W 6920AP3400A 5220AP3777C 6141AR3733V AJR30136901 EK-H2408C00 5400291617 5400315505 5400303915 5400296106 5400390201 5400390202 5400403001 5400305202 5400296908 5400290203 5400315402 5400290904 5400315301 5400292001 5400315204 5400157708 5400303002 5400300905 5400389601 5400301001 5400309601 5400309602 5400039411 5400289117 5400378101 5400310701 5400156408 5400156411 5400298301 5400278625 5400286702 5400287102 5400301404 5400303303 5400303304 5400303103 5400303104 5400126503 5400291721 5400158801 5400378203 5400057720 5400390301 REMARKS Indoor Motor Blower Side Pipe Sensor A-cycle Pipe Sensor B-cycle Outdoor Temp. Sensor For A-cycle For B-cycle PCM Fin Low Pressure Switch High Pressure Switch For Indoor Motor For Compressor For Outdoor Motor For Outdoor Motor For Heat Pump Service Manual 31 P/No.: 3828A31005F P/No.: 5400305106 Rev.:a