LG HBLG2504E, Service Manual

Page 1: ... Conditioner SERVICE MANUAL LG MODELS HBLG2504E LW250CE LWHD2500ER CAUTION website http www lgservice com BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE PERSONNEL ...

Page 2: ...pe 7 How to Install 8 Cabinet Installation 9 Operation 11 Function of Controls 11 Disassembly 12 Mechanical Parts 12 Air Handling Parts 13 Electrical Parts 14 Refrigerating Cycle 16 Schematic Diagram 19 Electronic Control Device 19 Wiring Diagram 20 Components Location 21 Troubleshooting Guide 22 Piping System 22 Troubleshooting Guide 23 Electrical Parts Troubleshooting Guide 25 Electric Parts 29 ...

Page 3: ...ndications Meanings of symbols used in this manual are as shown below WARNING CAUTION This symbol indicates the possibility of death or serious injury This symbol indicates the possibility of injury or damage to properties only Be sure not to do Be sure to follow the instruction WARNING Installation Do not use damaged power cord plugs or a loose socket There is risk of fire or electric shock Alway...

Page 4: ...ing and installing the product Sharp edges could cause injury Be especially careful of the case edges and the fins on the condenser and evaporator Do not store or use flammable gas or com bustibles near the air conditioner There is risk of fire or failure of product Be sure the installation area does not deterio rate with age If the base collapses the air conditioner could fall with it causing pro...

Page 5: ...W mm inch 660 25 31 32 H mm inch 449 17 11 16 D mm inch 721 28 13 32 Model Dimension HBLG2504E LW250CE LWHD2500ER Outside Dimensions This symbol alerts you to the risk of electric shock This symbol alerts you to hazards that could cause harm to the air conditioner This symbol indicates special notes NOTICE Symbols Used in this Manual ...

Page 6: ...OUTSIDE DIMENSION inch W x H x D mm 208 230V 60Hz 24 500 25 000 2 600 2 660 13 0 12 0 9 4 26 7 DB 19 4 WB 35 DB 23 9 WB 1 080g 38 1 oz 3 ROW 12 STACKS 3 ROW 20 STACKS TURBO FAN PROPELLER TYPE FAN WITH SLINGER RING 3 3 6 POLES REMOTE CONTROLLER THERMISTOR VERTICAL LOUVER RIGHT LEFT HORIZONTAL LOUVER UP DOWN SLIDE IN OUT CHASSIS OVERLOAD PROTECTOR INTERNAL THERMAL PROTECTOR 3 WIRE WITH GROUDING ATTA...

Page 7: ...ust be checked prior to initial starting The following items are especially important check points when the installation is finished 1 Grounding wire Green or Green and Yellow is provided in the power cord The green wire must be grounded 2 Connect to a single outlet 15A circuit or 20A circuit for Electric Heater Model 3 To avoid vibration or noise make sure the air conditioner is installed securel...

Page 8: ... the upper sash to the window stool 2 Installation Kits Contents 29 to 41 19 min Inner sill Offset Window Sash Sill Exterior Interior wall 26 min Without frame curtain 1 2 3 4 5 6 7 8 9 10 11 14 12 13 15 Top retainer bar is in the product package NO NAME OF PARTS Q TY 1 FRAME CURTAIN 2 2 SUPPORT BRACKET 2 3 SILL BRACKET 2 4 LOCK NUT 4 5 SCREW TYPE A 14 6 SCREW TYPE B 7 7 SCREW TYPE C 5 8 SCREW TYP...

Page 9: ...utward CAUTION Do not drill a hole in the bottom pan The unit is designed to operate with approximately 1 2 of water in bottom pan 4 Pull the bottom window sash down behind the Top retainer bar until they meet 1 Do not pull the window sash down so tightly that the move ment of Frame curtain is restricted Attach the cabinet to the window stool by driving the screws Type B through the cabinet into w...

Page 10: ...w locking bracket with a screw Type C See Fig 10 10 Attach the front grille to the cabinet by inserting the tabs on the grille into the tabs on the front of the cab inet Push the grille in until it snaps into place See Fig 11 11 Lift the inlet grille and secure it with a screw Type A through the front grille See Fig 11 12 Window installation of room air conditioner is now completed See ELECTRICAL ...

Page 11: ...ithin a range of 60 F to 86 F by 1 F 16 C to 30 C by 1 C Select the lower number for lower temperature of the room OPERATION MODE SELECTION BUTTON Every time you push this button it will shift among COOL ENERGY SAVER FAN and DRY Energy Saver If Energy Save mode is selected the fan stops when the compressor stops cooling a Approximately every 3 minutes the fan will turn on and check the room air to...

Page 12: ...Remove the front grille Refer to section 1 2 Remove the cabinet Refer to section 2 3 Remove the 2 screws which fasten the power cord 4 Disconnect the grounding screw from the evaporator channel 5 Remove the 1 screw that fastens the control box cover 6 Remove the housing that connects PCB and motor wire in the control box 7 Disconnect the housing that connects Plazma Air Purifier Optional 8 Remove ...

Page 13: ...ll out the hook of orifice by pushing the tabs and remove it See Figure 18 11 Remove the clamp with a hand plier that secures the turbo fan 12 Remove the turbo fan 13 Remove the 2 screws that fasten the air guide from the base pan 14 Move the air guide backward and pull out from the base pan Move the air giude lower carefully 15 Re install the components by referring to the removal procedure above...

Page 14: ...bove 8 Compressor 1 Remove the cabinet Refer to section 2 2 Discharge the refrigerant system using a FreonTM Recovery System If there is no valve to attach the recovery sys tem install one such as a WATCO A 1 before venting the FreonTM Leave the valve in place after servicing the system 3 Remove the overload protector Refer to sec tion 7 4 After purging the unit completely unbraze the suction and ...

Page 15: ...tion 3 2 Open the top cover from the control box Refer to section 9 3 Disconnect the front panel from the control box See Figure 24 4 Disconnect two leads from the capacitor and relay 5 Pull out the power cord 6 Re install the component by referring to the above removal procedure above Use only one ground marked hole for ground connection 7 If the supply cord of this appliance is damaged it must b...

Page 16: ...abinet Refer to section 2 2 Remove the 4 screws that fasten the brace Refer to section 4 3 Remove the 5 screws that fasten the condenser and shroud 4 After discharging the refrigerant completely unbraze the interconnecting tube at the con denser connections 5 Remove the condenser 6 Re install the components by referring to notes See Figure 26 13 Evaporator 1 Remove the control box Refer to section...

Page 17: ... pump and place it on the charging cylinder See figure 28B Open valve C Discharge the line at the manifold connection 5 The system is now ready for final charging 6 Recharge as follows 1 Refrigeration cycle systems are charged from the High side If the total charge cannot be put in the High side the balance will be put in the suction line through the access valve which you installed as the system ...

Page 18: ...of making a vapor proof seal Leak detector Tubing cutter Hand Tools to remove components Service valve A COMPOUND GAUGE EVAPORATOR LOW PRESSURE SIDE COMPRESSOR CAPILLARY TUBE CONDENSER HIGH PRESSURE SIDE SEE INSETS BELOW MANIFOLD GAUGE B Figure 28A Pulling Vacuum Figure 28B Charging A B EXTERNAL VACUUM PUMP A CHARGING CYLINDER LOW HI B C ...

Page 19: ...c R04G 4 d R05G 5 e R06G 6 f R07G 7 g 11 10 9 8 Tx ION MED HI KEY0 KEY1 LED out0 LED out1 LED out2 LED out3 Buzzer 5V 1 3 5 7 9 1 3 5 7 9 1 3 1 3 COMP d e g c a f b d e g c a f b d e g c a f b D01G SW01G TEMP DOWN SW02G D02G ON OFF SW03G D03G TIMER SW04G D04G MODE SW05G D05G TEMP UP SW06G D06G FAN HERM C RY COMP G4A 1A E LG RY HI RY MED RY LOW RY 4WAY CN TELE Q01T C104M Q02T A104M 5V Q04T A104M Q0...

Page 20: ...BK RD OR BR 1 5 7 6 8 4 2 3 MOTOR COMP CAPACITOR DC PCB ASSEMBLY THERMISTOR AIR FILTER ASSEMBLY AC PCB ASSEMBLY WIRING DIAGRAM 3854AR3563P SWITCH H V ASSEMBLY BK CN MOTOR CN PWR DC12V ZNR01J CN 12V CN HVB RY COMP 3 4 FUSE 250V T3 15A RY LOW RY MED RY HI CN AC DC POWER TRANS CN AC DC CN TH1 BL RD RD BK BL R S C OLP YL OR YL F C H WH BL Ribbed BK BR Plain GN YL GN GN YL GN BK RD OR BR S Service Part...

Page 21: ...SE RY COMP E05J E02J J8 E01J J6 J2 J3 RY HI ASSEMBLY 6871A20167 RY MED RY LOW RY 4WAY J7 J4 J1 D01T C02T Q02T CN CON CN 12V CN AC DC J12 J13 RECEIVER C02L J21 J22 J23 J18 J19 J17 BZ01E SW03G POWER SW06G TEMP UP SW02G TEMP DOWN SW05G MODE SW01G FAN SPEED C05D J04 CN AC DC J05 J01 J02 R01G R02G R03G R04G R05G R06G R07G R08G R09G CN TH1 SW04G TIMER J2ZD02F ZD01F C02A IC01A J08 J14 J15 J16 R10G J07 J0...

Page 22: ...cooling cycle MOTOR COMPRESSOR OIL LIQUID REFRIGERANT CAPILLARY TUBE OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH SUCTION LINE COOL LOW PRESSURE VAPOR COOLED AIR COMPLETE LIQUID BOIL OFF POINT LIQUID PRESSURE DROP ROOM AIR HEAT LOAD VAPOR INLET HOT DISCHARGED AIR LIQUID OUTLET HIGH PRESSURE VAPOR LIQUID REFRIGERANT LOW PRESSURE VAPOR ROOM AIR CONITIONER EVAPORATOR COILS CONDENSER COILS CYCLE O...

Page 23: ... operation Check gas leakage Repair gas leak Replacement of unit if the unit is beyond repair Satisfactory operation with temperature difference of inlet outlet air 44 50 F 7 10 C Check heat load increase Clean condenser Not on separate circuit Check inside gas pressure Adjusting of refrigerant charged Malfunction of compressor Replacement of compressor Check cold air circulation for smooth flow D...

Page 24: ...rregular motor insulation Replacement of fan motor Regular but fails to start Replacement of compressor locking of rotor metal Improper thermostat setting Loose terminal connection Improper wiring Irregular motor resistance Irregular motor insulation Replacement of compressor Motor damaged Drop of power voltage Capacitor check Replacement Compressor only fails to start Defect of compressor capacit...

Page 25: ...e voltage No 18 of Micom DC 5V Replace AC PCB Ass y Is the connection between AC and DC OK Is the reset circuit OK The No 14 of Micom is 5V Check the Fuse Check the wiring diagram Check the Main PCB pattern Replace the Trans Replace D02D D05D Replace IC01D Replace IC02D Replace IC01A C02A Connect connector exactly Check the PCB pattern NO NO NO NO NO NO NO YES YES YES YES YES YES YES NO YES Possib...

Page 26: ...Room Temp 0 5 C Is the voltage No 10 of IC01M 0V Replace IC01M Select the setting Temp to lower Number Wait 3 Minutes Does the Unit delay for 3 minutes Replace MAIN PCB Ass y Is the voltage N0 9 of IC01M DC 12V Check the RY COMP Check the wiring Diagram NO NO NO YES YES YES YES Is the wire connection of RY COMP OK Check the RY COMP Connect LEAD Wire to RY COMP again NO YES NO ...

Page 27: ... 1 or 2 or 4 of IC01M DC 12V Is the voltage NO 16 or 15 or 13 of IC01M 0V Check the RY Hi or RY Med or RY Lo Check the wiring diagram NO NO YES YES NO NO YES YES Is the mode key pushed once more from cool mode Is the voltage No 3 of CN AC DC of AC PCB Ass y DC 5V Reference to OWNER S MANUAL Set the mode key to Energy Saver mode Check the Energy Saver mode key Check the pattern of AC DC PCB ...

Page 28: ... Ass y Replace IC01G Replace IC03G Q01G Q02G Q03G for Delux Model Connect connector to CN AC DC exactly Does the IC03G Q01G Q02G Q03G for Delux Model operate normally on DC PCB Ass y Check the PCB pattern Is the voltage of Battery over 2 3V Replace Receiver Ass y Is the connection of CN AC DC OK Is the voltage No 10 of CN AC DC on DC PCB Ass y DC 5V Replace the battery Check the PCB pattern Connec...

Page 29: ...D DC 5V Is the voltage No 40 of Micom DC 5V Replace AC PCB Ass y Is the connection between AC and DC OK Is the reset circuit OK The No 14 of Micom is 5V Check the Fuse Check the wiring diagram Check the AC PCB pattern Replace the Trans Replace D02D D05D Replace IC01D Replace IC02D Replace IC01A C01A Connect connector exactly Check the PCB pattern NO NO NO NO NO NO NO YES YES YES YES YES YES YES NO...

Page 30: ...n Room Temp 0 5 C Is the voltage No 10 of IC01M 0V Replace IC01M Select the desired Temp to lower Number Wait 3 Minutes Is the Unit for 3 minutes delay Replace AC PCB Ass y Is the voltage N0 9 of IC01M DC 12V Check the RY COMP Check the wiring Diagram NO NO NO YES YES YES YES Is the wire connection of RY COMP OK Check the RY COMP Connect LEAD Wire to RY COMP again NO YES NO ...

Page 31: ...01M DC 5V Is the voltage NO 16 or 15 or 13 of IC01M 0V Check the RY Hi or RY Med or RY Lo Check the wiring diagram NO NO YES YES Check the PCB pattern Is the voltage of Battery over 2 3V Replace Receiver Ass y Is the connection of CN AC DC OK Is the voltage No 10 of CN AC DC on AC PCB Ass y DC 5V Replace the battery Check the PCB pattern Connect connector to CN AC DC exactly NO NO NO YES YES YES ...

Page 32: ... It displays abnormally on DC PCB Ass y NO NO NO NO YES YES YES Are the IC01G and IC02G good Is the connection of CN AC DC OK Replace the DC PCB Ass y Replace IC01G IC02G Replace IC03G Connect connector to CN AC DC exactly Does IC03G operate normally on AC PCB Ass y ...

Page 33: ... Does the fan blade rotate freely If not replace fan motor Pay attention to any change from high speed to low speed If the speed does not change replace the motor If cracked out of balance or partially missing replace it If cracked out of balance or partially missing replace it Tighten it If knocking sounds continue when running or loose replace the motor If the motor hums or noise appears to be i...

Page 34: ...um cleaner do not damage fins or brush Clean the interior base before reassembling If condenser fins are closed over a large area on the coil surface head pressures will increase causing the compressor to overload Straighten the fins or replace the coil Test capacitor Check the terminals If loose repair or replace Check the system for a restriction If restricted clean of replace Close if open Dete...

Page 35: ...0 147582 135312 152302 135313 147581 W48602 349480 349600 346811 130410 249950 352113 352111 238310 268714 135500 264110 237200 268712 263230 W0CZZ 149980 559011 W48602 554030 359012 349001 C TIMER PO WER MODE TE MP FA N SP EE D F1 LOW F2 ME D F3 HIG H Dr y Timer Fa n En erg y Sa ver Co ol 352390 1 352390 2 ...

Page 36: ...6871A20325A 6871A20325A 6871A20325A R 268714 PWB PCB ASSEMBLY MAIN AC 6871A20167D 6871A20167D 6871A20167D R 346811 MOTOR ASSEMBLY SINGLE 4681A20043K 4681A20043K 4681A20043K R 349001 DAMPER VENTILATION 4900A20016A 4900A20016A 4900A20016A R 349480 ORIFICE 4948A10024A 4948A10024A 4948A10024A R 349600 MOUNT MOTOR 4960A20056A 4960A20056A 4960A20056A R 352111 TUBE ASSEMBLY FORMED COND 5211A22013A 5211A1...

Page 37: ...Service Manual 37 Memo ...

Page 38: ...38 Room Air Conditioner Memo ...

Page 39: ...P No 3828A20306J Printed in Korea ...