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LG
LG Room
Air Conditioner
SERVICE MANUAL
MODELS: AS-W1863_ Series
AS-W2463_ 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..........................................................................................................................................5
Dimensions .....................................................................................................................................................9
Symbols Used in this Manual .....................................................................................................................9
Indoor Unit..................................................................................................................................................9
Outdoor Unit.............................................................................................................................................10
Product Specifications ................................................................................................................................11
Installation .....................................................................................................................................................12
Select the Best Location .........................................................................................................................12
Piping Length and Elevation.....................................................................................................................13
Fixing Installation Plate ............................................................................................................................13
Drill a Hole in the Wall ..............................................................................................................................14
Flaring Work.............................................................................................................................................14
Connection of Piping ................................................................................................................................15
Connecting the Cables .............................................................................................................................21
Checking the Drainage.............................................................................................................................23
Forming the Piping ...................................................................................................................................24
Air Purging ...............................................................................................................................................25
Test Running ............................................................................................................................................27
Functions .......................................................................................................................................................29
Operation .......................................................................................................................................................32
Disassembly ..................................................................................................................................................46
Indoor Unit................................................................................................................................................46
Schematic Diagram.......................................................................................................................................49
Wiring Diagram.........................................................................................................................................49
Components Location ..............................................................................................................................51
Troubleshooting Guide .................................................................................................................................55
Refrigeration Cycle Diagram ....................................................................................................................55
Pipe Length and the Elevation .................................................................................................................56
2-way, 3-way Valve ...................................................................................................................................57
Cycle Parts...............................................................................................................................................64
Self-diagnosis Function............................................................................................................................65
Electronic Parts ........................................................................................................................................67
Exploded View...............................................................................................................................................78
Indoor Unit................................................................................................................................................78
Outdoor Unit.............................................................................................................................................79
Replacement Parts List ................................................................................................................................80
Indoor .......................................................................................................................................................80
Outdoor ....................................................................................................................................................81
Service Manual 3
2003~2004
1 2 - 3 4 5 6 7 8 9 10
Dimensions
Symbols Used in this Manual
This symbol alerts you to the risk of electric shock.
This symbol alerts you to hazards that could cause harm to the
air conditioner.
NOTICE This symbol indicates special notes.
Indoor Unit
Installation plate
MODEL
18k, 24k Btu Series
DIM Unit
W mm 1170
H mm 315
D mm 173
Service Manual 9
Dimensions
Outdoor Unit
L2
L1
D
L3
L4
H
L11 L10
Gas side
Liquid side
L7 L6 L8 L9
L5
MODEL
18k, 24k Btu Series
DIM unit
W mm 870
H mm 655
D mm 320
L1 mm 370
L2 mm 340
L3 mm 25
L4 mm 630
L5 mm 25
L6 mm 546
L7 mm 162
L8 mm 162
L9 mm 54
L10 mm 74.5
Product Specifications
Table-1
Model Name
AS-W1863_ Series AS-W2463_ Series
Item Unit
W 1,612 4,430
MIN kcal/h.(W) 1,386 3,810
Btu/h. 5,500 15,120
W 5,274 7,032
Cooling Capacity Type kcal/h.(W) 4,536 6,048
Btu/h. 18,000 24,000
W 5,831 7,735
Max kcal/h.(W) 5,015 6,653
Btu/h. 19,900 26,400
W 1,670 4,190
MIN kcal/h.(W) 1,436 3,604
Btu/h. 5,700 14,300
W 6,065 7,946
Heating Capacity Type kcal/h.(W) 5,216 6,834
Btu/h. 20,700 27,120
W 6,739 8,351
Max kcal/h.(W) 5,796 7,182
Btu/h. 23,000 28,500
Power Input Cooling W 1,630 2,600
Heating W 1,890 2,800
Running Current Cooling A 7.5 11.5
Heating A 8.5 12.5
Starting Current Cooling A 7.5 11.5
Heating A 8.5 12.5
W/W 3.24 2.71
EER
Btu/h.W 11.04 9.23
COP W/W 3.21 2.84
Power Supply Ø,V,Hz 1,220-240,50 1,220-240,50
Power Factor % 96 98
Air Circulation Indoor,Max m3/min(CFM) 14.15(499) 16.64(587)
Outdoor,Max m3/min(CFM) 42(1483) 45(1587)
Moisture Removal l/h.(pts/h.) 2.4(5.1) 2.4(5.1)
Noise Level Indoor,High dB(A) 3 43/43 45/45
(Sound Med. dB(A) 3 40/40 41/41
Pressure,1m) Low dB(A) 3 37/37 36/37
Outdoor,Max dB(A) 3 56/57 56/57
Refrigerant(R410A)Charge 1200(42.3) 1490(52.6)
Power Cord AWG#:P*mm2 16:3*2.5 16:3*2.5
Connecting Cable AWG#:P*mm2 16:4*2.5 16:4*2.5
Connecting Tube Liquid Side mm(in) 6.35(1/4) 9.52(3/8)
(Ø. Socket Flare) Gas Side mm(in) 12.7(1/2) 15.88(5/8)
Length,std m(in) 7.5(295) 7.5(295)
Drain Hose (O.D , I.D) mm(in) 21.5,16.0(0.85,0.63) 21.5,16.0(0.85,0.63)
Indoor mm 1170*315*173 1170*315*173
Dimension inch 46.1*12.4*6.8 46.1*12.4*6.8
(W*H*D) Outdoor mm 870*655*320 870*655*320
inch 34.3*25.8*12.6 34.3*25.8*12.6
Net Weight Indoor kg(lbs) 13(28.7) 13(28.7)
Outdoor kg(lbs) 60(132.3) 60(132.3)
Service Manual 11
Installation
Installation
Select the best Location
Indoor unit
1. Do not have any heat or steam near the unit.
2. Select a place where there are no obstacles in front
of the unit. More than
3. Make sure that condensation drainage can be conve- 5cm More than 10cm
niently routed away.
4. Do not install near a doorway.
5. Ensure that the interval between a wall and the left More than
(or right) of the unit is more than 50cm. The unit 5cm
should be installed as high as possible on the wall, More than 2.3m
allowing a minimum of 10cm from ceiling.
6. Use a stud finder to locate studs to prevent unneces-
sary damage to the wall.
CAUTION: Install the indoor unit on the wall where the height from the
floor is more than 2 meters.
Outdoor unit
1. If an awning is built over the unit to prevent direct
sunlight or rain exposure, make sure that heat radia-
tion from the condenser is not restricted.
2. Ensure that the space around the back and sides is
more than 10cm. The front of the unit should have More than 60cm
more than 70cm of space.
3. Do not place animals and plants in the path of the More than 10cm More than 10cm
warm air.
4. Take the weight of the air conditioner into account
and select a place where noise and vibration are min-
imum. More
More than 70cm than 60cm
5. Select a place where the warm air and noise from the
air conditioner do not disturb neighbors.
Indoor unit
Outdoor unit
Outdoor unit
A A A
Oil trap
C A
Right rear piping
CHASSIS Distance (mm)
(Grade) A B C D
S3
58 3 292 3
(18k~24k)
Service Manual 13
Installation
CAUTION:
• The above circuit diagram is subject to change without notice.
• The earth wire should be longer than the common wires.
• When installing, refer to the circuit diagram behind the panel front of the indoor unit.
• Connect the wires firmly so that they may not be pulled out easily.
• Connect the wires according to color codes, referring to the wiring diagram.
CAUTION: The power cord connected to the "A" unit should be selected according to
the following specifications(Type "B" approved by HAR or SAA).
(mm2)
Grade
NORMAL CROSS
18k 24k
-SECTIONAL AREA
2.5 2.5
Unit(A) Indoor Indoor
Cable Type(B) H05VV-F H05VV-F
The power connecting cable connecting the indoor and outdoor unit should be selected
according to the following specifications (Type "B" approved by HAR or SAA).
(mm2)
NORMAL Grade
CROSS
18k 24k
-SECTIONAL
AREA 2.5 2.5
Cable Type(B) H07RN-F H07RN-F
Service Manual 21
Installation
Outdoor
1. Remove the control cover from the unit by loosening Outdoor Unit
the screw.
Connect the wires to the terminals on the control Terminal block
board individually.
2. Secure the cable onto the control board with the cord
Over 5mm
clamp.
3. Refix the control cover to the original position with the
screw. Connecting cable
Circuit Grade
Breaker 18k 24k
(A) 20 30
Functions
Indoor Unit
Service Manual 29
Functions
Outdoor Unit
V/F control
• It will be changed the drive voltage of comp. according to operating frequency.
• High speed
- Although fan motor speed is middle, it will change high speed in case of below AC193V, over 45°C of
outdoor temp., and over fc, fh of comp. Freq.
• Middle speed
- Nomal mode
• Low speed
- Although fan motor speed is middle, it will change Low speed in case of over AC 270V, over 21°C
(Heating Mode) of outdoor temp. below 24°C (Cooling Mode) of outdoor temp.
Low ambient
Remote Control
Operation ON/OFF
JET COOL
PLASMA(Optional)
PLASMA
Timer Selection
ON OFF
: OFF, ON, OFF ON
Timer Setting
SET
Timer Cancel
CANCEL
: Cancel Sleep Mode, Timer ON or Timer OFF
Sleep Operation
: 1, 2, 3, 4, 5, 6, 7, Off Timer
Airflow Direction Control
Reset
Service Manual 31
Operation
Operation
LED display of indoor unit
■ LG Brand/OEM Brand
• On while in appliance operation, off while in appliance pause.
Operation Indicator • Blinking(3sec off/0.5sec on) according to Error Code as long as the system malfunctions.
Sleep Timer Indicator • On while in sleep timer mode, off when sleep timer cancel or appliance operation pause.
PLASMA Indicator • On while in plasma mode, off when plasma mode cancel.
Timer Indicator • On while in timer mode(on/off), off when timer mode is completed or canceled.
Preheat Indicator • Off except when hot start during heating mode operation or while in defrost control.
PLASMA
Indoor pipe
Comp. free temp.
6˚C 7˚C
Comp. Step 4
3˚C Comp. Step 2
0˚C
Comp. off
Protection of the indoor fan from droplet formation (Enclosure sweat and condensed disposal test)
• Control condition : The system operates standard operation without this condition as follows.
Setting temperature <25°C
Indoor fan speed ≤ low speed
Outdoor temperature < 30°C
• Control method
In operation for 5~20 minutes in , , conditions, return to the previous COMP STEP after operation for
5~40 minutes at the COMP STEP 3.
Service Manual 33
Operation
AS-W2463_ Series 35 42 49 55 62 65 72
18°C < intake air temp. < 24°C intake air temp. -0.5°C
• When intake air temp reaches above the temp of setting +1.0°C, condition of compressor same as cooling
mode operation.
• When intake air temperature reaches bolow the temp of setting –1.0°C, compressor operate step1~step3 and
indoor fan speed repeatly operate low or stop.
Service Manual 35
Operation
Service Manual 37
Operation
2. Fuzzy operation for Heating
• According to the setting temperature selected by Fuzzy rule, the operating frequency of compressor is deter-
mined like heating mode operation.
• At the beginning of Fuzzy mode operation, the setting temperature is automatically selected according to the
intake air temperature at that time.
• When the Fuzzy key(=setting temp. key) is input after the initial setting temperature is selected, the Fuzzy
key value and intake air temperature at that time are compared to select the setting temperature automatical-
ly according to the Fuzzy rule.
• While in Fuzzy operation, the airflow speed of the indoor fan is automatically operated by Fuzzy logic.
Swing mode
1. Chaos swing mode
• By the Chaos swing key input, the upper/lower vane automatically operates with the Chaos swing or it is
fixed to the desired direction.
CLOSED
Chaos Swing On
Mode 9
Mode 8
Mode 7
Mode 6
Mode 5
Mode 4
Mode 3
Chaos Swing Mode 2
Mode 1
The first path
OPEN
Service Manual 39
Operation
Cooling ON temp.
(Setting temp. +0.5˚C)
Forced operation
• To operate the appliance by force in case that the remote control is lost, the forced operation selection switch
is on the main unit of the appliance to operate the appliance in the standard conditions.
• The operation condition is set according to the outdoor temp. and intake air temperature as follows.
Setting speed of
Indoor temp. Operating Mode Setting temp.
indoor fan
Trial Operation
• Press the Tact Switch for compulsory operation of the main body for 3 seconds in order to operate in the trial
operation mode.
- Operation mode: Cold
- Indoor pan: Strong wind
- COMP frequency: Step 5
- COMP compulsorily operates for about 18 minutes irrespective of indoor temperature.
Service Manual 41
Operation
■ CT2 control
• If the operating current of the appliance reaches I2, the compressor stop instantly and 2 minutes later the
compressor restart again.
• If CT2 occurs 5 times within 1hour, the appliance turn off and display ERROR CODE 7.
I1
Model Outdoor temp ≥ 38°C Outdoor temp < 38°C I2
Cooling Heating Cooling Heating
1 AS-W1863_ Series 10.5 11.5 11 12 14.0
2 AS-W2463_ Series 13.5 14.0 14 14.5 15.5
cf. I1 is set the lowest level between intial value and in case dectection of dc paeak current.
T1 °C
T on °C
COMP
Freq. Free Fc-1 Fc-2 Fc-1 Fc-2 OFF Free
COMP Freq. Fh min Free Fc-1 Fc-2 OFF Fc-2 Fc-1 Free
Service Manual 43
Schematic Diagram
Schematic Diagram
Electric Control Device
Indoor Unit
CN-MOTOR
WCN-NOISE
MAIN PCB
ASM
GN/YL
SSR
CN-TH
OR
THERMISTOR
MOTOR
BK ZNR01F
BR
SH-CAPA.
BL CN-IN
CN-U/D
STEP
MOTOR
BL CN-OUT
CN-HVB CN-L/R
BR STEP
FUSE
4 3 AC250V/T2A MOTOR
RY-PWR RD RD
H.V.B A/CL
CN-COM BK BK
GN/YL
RD
BR
BL
TERMINAL
1(L) 2(N) 3 BLOCK
GN/YL
CN-SW/2 CN-SW/3
CN-MAIN
RD
BR
BL
LIMIT S/W-1
CN-SW/1
FORCED CONNECTOR
OPERATON PWB ASM
S/W LIMIT S/W-2
CN-STEP1 CN-STEP2
TO OUTDOOR UNIT
SUC SUC
STEP STEP
MOTOR-1 MOTOR-2
3854A20305E
AS-W2463_ Series
POWER
WCN-NOISE
MAIN PCB
ASM
GN/YL
RD
CN-MOTOR1
CN-TH
THERMISTOR
FAN BK
MOTOR WH
DISPLAY PWB ASM
BL
CN-DISP1
YL
BL
CN-OUT CN-IN/N
CN-U/D
STEP
BR
MOTOR
FUSE
4 3 AC250V/T2A
CN-HVB CN-L/R
STEP
RY-PWR MOTOR
RD RD
H.V.B A/CL
CN-COM BK BK
GN/YL
RD
BR
BL
TERMINAL
1(L) 2(N) 3 BLOCK
GN/YL
CN-SW/2 CN-SW/3
CN-MAIN
RD
BR
BL
LIMIT S/W-1
CN-SW/1
FORCED CONNECTOR
OPERATON PWB ASM
S/W LIMIT S/W-2
CN-STEP1 CN-STEP2
TO OUTDOOR UNIT
SUC SUC
STEP STEP
MOTOR-1 MOTOR-2
3854A20305H
Service Manual 49
Schematic Diagram
Outdoor Unit
AS-W1863_ Series
RY-4WAY
WCN-NOISE 4(BK)
RY-H
WCN-NOISE 1(BK)
TERMINAL
BLOCK 15A/AC 250V
TO INDOOR UNIT
BR
1(L) 2(N)
FUSE RD CN-U
BL + + +
BL CN-V
GN/YL
SPM2 COMP
YL CN-W
RD
3
WCN-NOISE 3(BK)
3854A20310M
AS-W2463_ Series
REVERSING HEAT SINK OUTDOOR PIPE TH. COMP TH.
OUTDOOR WIRING DIAGRAM VALVE TH. TH.
REACTOR
Motor
BK BK
BK OR YL
WCN-NOISE 4(BK)
RY-H
WCN-NOISE 1(BK)
TERMINAL
BLOCK 20A/AC 250V
TO INDOOR UNIT
BR
1(L) 2(N)
FUSE RD CN-U
BL + + +
BL CN-V
GN/YL
SPM2 COMP
YL CN-W
RD
3
WCN-NOISE 3(BK)
3854A20310C
Oil trap A
A
Cycle Parts
Trouble analysis
1. Check temperature difference between intake and discharge air and operating current.
NOTICE
Temperature difference between intake and discharge air depends on room air humidity. When the room air
humidity is relativery higher, temperature difference is smaller. When the room air humidity is relatively lower tem-
perature difference is larger.
NOTICE
1. The suction pressure is usually 8.5~9.5kg/cm2G(Cooling) at normal condition.
2. The temperature can be measured by attaching the thermometer to the low pressure tubing and wrap it with
putty.
Self-diagnosis function
1. The malfunction indicator of indoor (see the operating LED of the INDOOR)
Outdoor TH. is short or open. The display show "C2" Keep operating state.
2
Temp. of Heat sink is over 95°C. The display show "C4" Restart compressor when Heat sink
4
/Heat sink TH. is short or open. Temp is 85°C below.
Comunication error (serial The display show "C5" The operation is off(enable to restart
5 comunication). by remote controller).
DC peak error. The display show "C6" Compressor will be turned off immediately.
6 (not enable to restart by remote controller)
Running current is over- The display show "C7" Compressor will be turned off immediately.
7 loaded. (CT2) (not enable to restart by remote controller)
Indoor fan lock error The display show "C8" The operation is off(enable to restart
8
(BLDC fan model) by remote controller).
Outdoor fan lock error The display show "C9" The operation is off(enable to restart
9
(BLDC fan model) by remote controller).
D-PIPE TH is short or open. The display show "CA" Compressor will be turned off immediately.
10 (restart compressor when D-PIPE TH. is
recovred)
❈ Error code ➅, ➆ can’t be operated unless the power cord is removed.
2. The malfunction indicator of outdoor (see the LED01M on the outdoor PCB ass’y)
Comunication error (serial The LED01M will be blinking 5 The operation is off(enable to restart
5
comunication). times. by remote controller).
DC peak error. The LED01M will be blinking 6 Compressor will be turned off immediately.
6
times. (not enable to restart by remote controller)
Running current is over- The LED01M will be blinking 7 Compressor will be turned off immediately.
7
loaded. times. (not enable to restart by remote controller)
Outdoor fan lock error The LED01M will be blinking 9 The operation is off(enable to restart
9 (BLDC fan model) times. by remote controller).
D-PIPE TH is short or open. The LED01M will be blinking 10 Compressor will be turned off immediately.
10 (restart compressor when D-PIPE TH. is
times. recovered)
Service Manual 65
Troubleshooting Guide
Indoor Outdoor
Electronic Parts
❇ Refer to electronic contorol device drawing & schematic diagram.
NO YES
Service Manual 67
Troubleshooting Guide
While the compressor has been stopped, the compressor does not operate
owing to the delaying function for 2 minutes after stopped.
When the mark ( ) is displayed in LCD Check the contact of CN-DISP 1, 2 connector
screen, replace battery.
Check point
• Check the connecting circuit between
MICOM PIN and CN-DISP1 PIN
• Check receiver ass'y
Operate Cooling Mode by setting the disired temperature of the remote controller is less
than one of the Indoor temperature by 1°C at least.
Check the sensor for Indoor temperature is attatched as close as to be effected by the
themperature of Heat Exchange (EVA.)
When the sensor circuit for Indoor temperature and connector are in bad connection or are
not engaged, Compressor/Outdoor fan is stopped.
• Check the related circuit of R02H(12.1K), R01H(6.2K), R04H(1K), R03H(1K), C01H(102),
C02H(102), Micom(pin No. , ).
• Check the Indoor temperature sensor is disconnected or not (Resistance is about 10K at 25°C).
Service Manual 69
Troubleshooting Guide
• The pin No.45 of micom and the part for driving SSR.
• Check the related pattern.
• Check the SSR.
- SSR Open: Indoor Fan Motor never operate.
- SSR short: Indoor Fan Motor always operates in case of ON or OFF.
• Confirm that the vertical louver is normally geared with the shaft of Stepping Motor.
• If the regular torque is detected when rotating the vertical louver with hands ⇒ Normal
• Confirm the assembly condition that are catching and interfering parts in the link of the
vertical louver
Service Manual 71
Troubleshooting Guide
• Check the connecting condition of CN-PTC connector on the indor DC P.C.B Ass'y.
• Check the soldering condition of CN-PTC connector on the indoor DC P.C.B Ass'y.
• Check the pattern between MICOM Pin No. 48 → IC02M Pin No. 7 → IC02M Pin No. 10 → CN-PTC
• Inner side disconnection of PTC Heater unit or restriced operating condition of PTC Heater
(pipe temp. is over 45°C, defrosting operation, compressor off, indoor fan off).
YES
Does the Operating LED of indoor unit blink
Refer to the self-diagnosis function.
when Operation's ON?
NO
NO
Is the Connection between indoor power Check the connecting state of connector
relay Pin ➂ and terminal block No. 1 right?
YES
NO
Indoor Outdoor
Is the connection of cable between indoor
and outdoor unit right? 1(Brown) 1(Brown)
2(Blue) 2(Blue)
3(Green/YL) 3(Green/YL)
YES 4(Red) 4(Red)
NO
Is the voltage of Terminal Block , in
Check the Fuse of Outdoor PCB Ass'y.
outdoor Control Box about AC220V /
240V?
YES
NO
Is the voltage of NF01J ➀, ➁ in outdoor
Check the PTC and RY-PWR.
PCB Ass'y about AC220V / 240V when
Operation's ON?
YES
NO
NO
Service Manual 73
Troubleshooting Guide
YES
NO
Is the connecting state of connectors in out- • Electrical wiring diagram (Colors)
door. PCB Ass'y right? • Check the connecting state of connectors
(CN-UVW) in PCB Ass'y
• If CN-UWV is connected, the comprressor
YES can be operated a opposite direction.
NO
• Check the short P-N P-U, V, W, and N-U,
Is the power module in PCB Ass'y right?
V, W of IPM and then collector, emiter of
IGBT
YES
NO
Is the voltage of T/Block , over than
AC150V? Check the supplied voltage.
YES
NO
Is the voltage of GND-IPM(32 pin) over • Check the DC voltage between IPM 1pin
than about DC280V? GND
YES
NO
Supply the refrigerant or Discharge refriger-
Is the refrigerant pressure right?
ant.
NO
YES
NO
Is the voltage of BR/BK, RD AC220/240V in • Electrical wiring diagram(Colors)
Main PCB Ass'y. • Check the connecting state
of connectors in outdoor PCB Ass'y
• Check the Fuse of outdoor PCB Ass'y.
YES
NO
Is the connection of CN-T/Block and in • Reconnect the connectors.
CN-AC/DC indoor P.C.B Ass'y is right? • Check the PCB pattern(Resoldering).
YES
Service Manual 75
Troubleshooting Guide
YES
NO
Is the courrent transformer(CT) in Main
PCB Ass'y right? Check the PCB pattern(resoldering)
YES
NO
YES
NO
YES
NO
YES
Service Manual 77