website http://www.lgservice.com LG 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.
Air Conditioner Service Manual TABLE OF CONTENTS LG Model Name ...............................................................................................................................................3 Safety Precautions..........................................................................................................................................4 Dimensions ......................................................................................................................................
LG Model Name 2003 1 Code 2 - 3 Type 4 5 6 Code of Model 7 8 9 10 Meaning 1 Producing Center, Refrigerant A~Z L: Chang-won R22 A: Chang-won R410A C: Chang-won R407C T: China K: Turkey R22 E: Turkey R410A H: Thailand N: India Z: Brazil D: Indonesia M: Mexico V: Vietnam S: Out Sourcing 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 4, 5 Capacity 0~9 Cooling/Heating Capacity Ex.
Safety Precautions 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 following indications. This symbol indicates the possibility of death or serious injury. 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.
Safety Precautions Ensure that an installation frame of the outdoor unit is not damaged due to use for a long time. • It may cause injury or an accident. Do not disassemble or repair the product randomly. • It will cause a fire or electrical shock. Do not install the product at a place that ther is concern of falling down. • Otherwise, it may result in personal injury. ■ Operation Use caution when unpacking and installing. • Sharp edges may cause injury. Do not modify or extend the power cord randomly.
Safety Precautions Keep the flames away. • Otherwise, it may cause a fire. Do not open the suction inlet of the indoor/outdoor unit during operation. • Otherwise, it may electrical shock and failure. Take the power plug out if necessary, holding the head of the plug and do not touch it with wet hands. • Otherwise, it may cause a fire or electrical shock. Do not allow water to run into electrical parts. • Otherwise, it may cause a fire and electrical shock.
Safety Precautions ■ Installation Install the drain hose to ensure that drain can be securely done. • Otherwise, it may cause water leakage. 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 dispute with the neighbors. • Otherwise, it may cause the failure of product. ■ Operation Keep level parallel in installing the product.
Dimensions 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.
Dimensions Outdoor Unit L2 D L1 W H L3 L5 Gas side (3-way valve) L4 Liquid side (2-way valve) DIM MODEL unit AS-H076PB/D/M/WL1 W mm 575 H mm 525 D mm 260 L1 mm 301 L2 mm 73 L3 mm 392 L4 mm 35 L5 mm 100 Service Manual 9
Dimensions L2 D L1 W H L3 L5 Gas side (3-way valve) L4 Liquid side (2-way valve) DIM MODEL unit AS-H096PB/D/M/WL1, AS-H126PB/D/M/WL1 W mm 770 H mm 540 D mm 245 L1 mm 285 L2 mm 64 L3 mm 518 L4 mm 10 L5 mm 100 10 Room Air Conditioner
Product Specifications Product Specifications Table-1 Model Name AS-H076PB/D/M/WL1 AS-H096PB/D/M/W/L1 Item A-12AH series Unit 7500 9200 12000 7700 9400 12200 l/h 1 1.2 1.5 Ø, V, Hz 1Ø, 220-240V, 50Hz 1Ø, 220-240V, 50Hz 1Ø, 220-240V, 50Hz 5.5 6.8 8.3 20 26 26 37 39 44 48 48 48 685 840 1099 705 860 1200 3 3.8 4.9 3.1 3.85 5.3 10.95 10.95 10.92 3.2 3.2 2.98 24 24 24 18 25.5 25.
Installation Installation Selection of the Best Location Indoor unit • Do not have any heat or steam near the unit. • Select a place where there are no obstacles in front of the unit. • Make sure that condensation drainage can be conveniently routed away. Do not install near a doorway. • 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.
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.
Installation Fixing the Indoor Unit 1. Attach an Installation guide map on the desired surface. INSTALLATION GUIDE MAP 6. Look at suited horizon by horizontal meter on the horizontal setting line, and fix lightly the map by adhesive tape. Horizontality 2. Make a hole with a diameter of 6mm and depth of 30-35mm by piercing a screw point. IN ST AII AT IO N IN ST AL LA TIO N GU ID EM AP 7. Drill the pierted part as a diameter of 50mm for connecting piping.
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 locally. Copper pipe Slanted Uneven Rough 90° 2. Measure the distance between the indoor and the outdoor 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.
Installation Check Smooth all round 1. Compare the flared work with the figure by. Inside is shiny without scratches 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.
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 mm inch Ø6.35 1/4 Ø9.52 3/8 Ø12.7 1/2 Ø15.88 5/8 Ø19.05 3/4 Torque kg.m 1.8 4.2 5.5 6.6 6.6 Open-end wrench (fixed) Flare nut Connection pipe Wrench Indoor unit tubing 3.
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. • When tightening the flare nut with torque wrench, ensure the direction for tightening follows the arrow on the wrench. Outside diameter mm inch Ø6.35 1/4 Ø9.52 3/8 Ø12.7 1/2 Ø15.88 5/8 Ø19.05 3/4 18 Room Air Conditioner Torque kg.m 1.8 4.2 5.5 6.6 6.
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.
Installation Connecting the Cables to the Outdoor Unit 1. Remove the control cover from the unit by loosening the screw. Connect the wires to the terminals on the control board individually. Outdoor Unit Terminal block 2. Secure the cable onto the control board with the cord clamp. 3. Refix the control cover to the original position with the screw. Over 5mm Connecting cable Connecting cable 4. Use a recognized circuit breaker "A" between the power source and the unit.
Installation Checking the Drainage Forming the Piping 1. Checking the drainage. • 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. 1. Form the piping by wrapping the connecting portion of the indoor unit with insulation material and secure it with two kinds of vinyl tapes. • If you want to connect an additional drain hose, the end of the drain outlet should be routed above the ground.
Installation Air Purging Air and moisture remaining in the refrigerant system have undesirable effects as indicated below. • Pressure in the system rises. • Operating current rises. • Cooling(or heating) efficiency drops. • Moisture in the refrigerant circuit may freeze and block capillary tubing. • Water may lead to corrosion of parts in the refrigeration system. Therefore, the refrigerant system must be leak tested and evacuated to remove any noncondensables and moisture from the system.
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 counterclockwise 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 connections by a soft brush to check for leakage of the connecting points of the piping. (5) If bubbles come out, the pipes have leakage. 3.
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.
Test Running Intake temperature 1. Check that all tubing and wiring have been properly connected. 2. Check that the gas and liquid side service valves are fully open. Discharge air Prepare remote controller 1. Remove the battery cover by pulling it according to the arrow direction. 2. Insert new batteries making sure that the (+) and (–) of battery are installed correctly. 3. Reattach the cover by pushing it back into position. NOTICE Discharge temperature 4.
Operation 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.
Operation ■ 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.
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.
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.
Operation ■ 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. ■ 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.
Operation - Operation Mode/Setting Temp/Selected Airflow Speed - Sleep Timer Mode/Remaining Time of Sleep Timer (unit of hour) ■ 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. Cooling Model Operating mode Indoor Fan Speed Setting Temperature Cooling High 22°C Heat pump Model Room Temp. ≥ 24°C 21°C ≤ Room Temp. < 24°C Room Temp.
Operation ■ 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.
Operation Display Function 1. Heating Model Operation Indicator • Cooling, Soft Dry, Fan, Heating Sleep Timer Indicator • Sleep Mode Timer Indicator • Timer Mode Defrost Indicator 2.
Operation Self-diagnosis Function Error Code Error Display LED (Indoor body operation LED) (once) 1 3sec 34 Room Air Conditioner 3sec 3sec Error contents • Indoor room temperature thermistor open/short • Indoor pipe temperature thermistor open/short.
Operation Remote Control Operations The controls will look like the following. Controls Signal transmitter 5 1 6 3 4 2 7 11 8 13 10 CANCEL ON OFF 9 12 SET AUTO CLEAN 17 14 15 16 Flip-up door (opened) Operation Mode Cooling Operation Auto Operation or Auto Changeover Healthy Dehumidification Operation Heating Operation • Cooling Model( ), Heat Pump Model( ) 1. START/STOP BUTTON Operation starts when this button is pressed and stops when the button is pressed again. 2.
Disassembly 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.
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.
LED3 PLASMA LED2 PLASMA LED1 PLASMA Vout GND Vcc RECEIVER 10 Digit2 LED1 ON/OFF LED4 DEFROST LED3 TIMER LED2 SLEEP DISPLAY STEPPING MOTOR 흡입구 1 d g 2 2 e f 1 1 8(c) 7(e) 6(d) 9(b) 1(g) 3(a) FAN MOTOR 14 14 14 15 RD BK YL BL WH 1 2 3 4 3 4 7 6 7 6 5 2 2 5 1 1 3 1 3 2 2 2 3 1 1 3 15 14 15 14 13 12 12 12 12 13 11 11 11 11 13 10 10 10 10 13 8 9 8 9 8 7 6 5 4 3 2 1 CN-D2 8PIN CN-D2 7PIN CN-MOTOR1(WH) CN-12V(WH) C
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
Schematic Diagram Components Location MAIN P.W.B ASSEMBLY (AC PART) • HEAT PUMP MODEL PWB : 6870A90161D R14D R10D R11D Q01G C12D C11D SMPS ZD02D R05D L3 C03D D05D CN-ACDC1 R08D R09D D06D Q02G R16D C10D C02D CY5 D02D D03D L1 IC07D IC08D IC05D IC06D C09D R13D ZD01D IC02D R07D R06D IC01D NF01N PWB ASM : 6871A10121 MAIN P.W.
Schematic Diagram DISPLAY ASSEMBLY – 6871A20462 TOP VIEW BOTTOM VIEW SUB P.W.
Troubleshooting Guide Troubleshooting Guide Refrigeration Cycle Diagram (1) Cooling Only Models INDOOR UNIT OUTDOOR UNIT LIQUID SIDE CAPILLARY TUBE HEAT EXCHANGE (CONDENSER) HEAT EXCHANGE (EVAPORATOR) GAS SIDE COMPRESSOR (2) Cooling & Heating Models INDOOR UNIT OUTDOOR UNIT LIQUID SIDE CHECK VALVE (Heating Model only) 3-WAY VALVE CAPILLARY TUBE HEAT EXCHANGE (EVAPORATOR) HEAT EXCHANGE (CONDENSER) GAS SIDE 3-WAY VALVE REVERSING VALVE (Heating Model Only) ACCUMU LATOR COMPRESSOR 42 Room Air Co
Troubleshooting Guide 2-way, 3-way Valve 2-way Valve (Liquid Side) Hexagonal wrench (4mm) Flare nut 3-way Valve (Gas Side) Valve cap Open position Flare nut Closed position Open position Closed position To piping connection To piping connection To outdoor unit Works Shipping 1.
Troubleshooting Guide Pumping Down Liquid side Indoor unit 2-Way valve Open Outdoor unit Gas side Closed 3-Way valve Lo CLOSE CLOSE Purge the air • 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.
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 Lo OPEN CLOSE • Procedure (1) Confirm that both the 2-way and 3-way valves are set to the back seat. (2) Connect the charge set to the 3-way valve’s port. – Leave the valve on the charge set closed. – Connect the charge hose to the service port.
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 Lo OPEN CLOSE • 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 -76 cmHg (vacuum of 4 mmHg or less).
Troubleshooting Guide Gas Charging (After Evacuation) Liquid side Indoor unit 3-Way valve Open Outdoor unit Gas side Open 3-Way valve Check valve Charging cylinder Lo (1) OPEN CLOSE • Procedure \ (1) Connect the charge hose to the charging cylinder. – Connect the charge hose which you dis-connected 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 system can be charged with liquid.
Troubleshooting Guide Cycle Parts Trouble analysis 1. Check temperature difference between intake and discharge air and operating current. Temp. Difference Operating Current Temp. difference : approx. 0°C Current : less than 80% of rated current • All amount of refrigerant leaked out. Check refrigeration cycle. Temp. difference : approx. 8°C Current : less than 80% of rated current • Refrigerant leakege Clog of refrigeration cycle Defective compressor Temp.
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 NO Primarily, the operating condition of Micom is OK.
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.) Cause by the remote control When the mark( battery.
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).
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.
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.
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).
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.
Room Air Conditioner 135314 135312 268717 159830 152302 268712 267110 264110 249951 146811 359012 144710-1 268714-2 268714-1 146811 144710-2 146811 135500-3 349600 346810 135311-1 147581 330870 354210 135311-3 146811 135500-2 352380 135500-1 147581 263230 35211B 131410 352150 352116 352115 135515 146811 147581 135311-2 Exploded View Exploded View Indoor Unit
Exploded View Outdoor Unit (AS-H076PB/D/M/WL1) 437210 437212 554031 435301 435511 546810 552102-2 559010 649950 552201 552111 552102-1 W0CZZ 552116 552202 567502 561410 554160 447910 550140 552203-1 430410 552203-2 Service Manual 57
Exploded View Outdoor Unit (AS-H096PB/D/M/WL1, A-12AH..
Replacement Parts List Replacement Parts List Indoor Unit LOCATION No. PART No.
Replacement Parts List Outdoor Unit LOCATION No. DESCRIPTION 430410 BASE ASSY,OUTDOOR 435301 GRILLE,DISCHARGE 435511 PART No.
Memo Service Manual 61
Memo 62 Room Air Conditioner
P/No.