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LG AS-W1863 Series Svc Manual
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LG AS-W1863 Series Svc Manual

LG AS-W1863 Series Svc Manual

Universal air conditioner
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http://biz.lgservice.com
Universal Air Conditioner
SVC MANUAL(Exploded View)
MODEL : AS-W1863_ Series
AS-W2463_ Series
CAUTION
Before Servicing the unit, read the safety precautions in General SVC manual.
Only for authorized service personnel.

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Summary of Contents for LG AS-W1863 Series

  • Page 1 Internal Use Only http://biz.lgservice.com Universal Air Conditioner SVC MANUAL(Exploded View) MODEL : AS-W1863_ Series AS-W2463_ Series CAUTION Before Servicing the unit, read the safety precautions in General SVC manual. Only for authorized service personnel.

  • Page 2: Table Of Contents

    Pipe Length and the Elevation .........................57 2-way, 3-way Valve ...........................58 Cycle Parts...............................65 Self-diagnosis Function..........................66 Electronic Parts ............................68 Exploded View...............................79 Indoor Unit..............................79 Outdoor Unit.............................80 - 2 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 3: Lg Model Name

    GOLD FIN LG/OEM Brand L: LG Brand M: 1st OEM Brand G: 2nd LG Brand N: 2nd OEM Brand - 3 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 4 Nano Plasma F+4Way+(A/changeove)+A/clean+ Serial No. LG Model De velopment Serial No. * ARTCOOL COLOR Mirror White Blue Wood Metal Cherry - 4 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 5: Safety Precautions

    • There is risk of fire, electric shock, • Shape edges could cause injury. shock. explosion or injury. Be especially careful of the sharp edges. - 5 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 6 • There is risk of fire or electric • There is risk of fire or electric shock. shock. - 6 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 7 • A bad connection may cause water • To avoid vibration or water leak- failure of product. leakage. age. 90˚ - 7 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 8 • There is risk of personal injury and • There are sharp and moving parts failure of product. that could cause personal injury. - 8 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 9: Dimensions

    This symbol indicates special notes. NOTICE Indoor Unit Installation plate MODEL 18k, 24k Btu Series Unit 1170 - 9 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 10: Outdoor Unit

    Dimensions Outdoor Unit Gas side Liquid side MODEL 18k, 24k Btu Series unit 74.5 - 10 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 11: Product Specifications

    46.1*12.4*6.8 46.1*12.4*6.8 (W*H*D) Outdoor 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) - 11 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 12 Energy Labeling Capacity Cooling 6.00 Heating 1.69 Energy Consumption Cooling 2.05 Heating Star Rating Cooling Heating S3+UE Tool (IN/OUT) - 12 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 13: Installation

    60cm 5. Select a place where the warm air and noise from the air conditioner do not disturb neighbors. - 13 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 14: Piping Length And Elevation

    Installation plate be done safely. Right rear piping Distance (mm) CHASSIS (Grade) (18k~24k) - 14 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 15: Drill A Hole In The Wall

    Cone Ø6.35 0~0.5 Ø9.52 0~0.5 Copper pipe Ø12.7 0~0.5 Clamp handle Ø15.88 0~1.0 Red arrow mark Ø19.05 1.0~1.3 - 15 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 16: Connection Of Piping

    "sweating"(condensation) will not damage fur- Tape niture or floors. Connecting pipe *Foamed polyethylene or equivalent is recom- Drain hose mended. Connecting cable - 16 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 17 Wrap with vinyl tape they fit into the rear piping housing section. Pipe Vinyl tape(wide) Drain hose - 17 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 18 3. When extending the drain hose at the indoor unit, install the drain pipe. Drain hose Indoor unit drain hose Vinyl tape (narrow) Adhesive - 18 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 19 3. Press the lower left and right sides of the unit against Connecting the installation plate until the hooks engage into their cable slots(clicking sound). Drain hose - 19 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 20 • Press on the upper side of clamp and unfold the tubing to downward slowly. Bad case • Following bending type from right to left may cause damage to the tubing. - 20 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 21 Gas side piping (Bigger diameter) Outside diameter Torque inch kg.m Ø6.35 Ø9.52 Ø12.7 Torque wrench Ø15.88 Ø19.05 - 21 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 22: Connecting The Cables

    (Type "B" approved by HAR or SAA). NORMAL Grade CROSS -SECTIONAL AREA Cable Type(B) H07RN-F H07RN-F - 22 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 23 9. The means for disconnection from a power supply shall be incorporated in the fixed wiring and have an air gap contact separation of at least 3mm in each active(phase) conductors. - 23 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 24: Checking The Drainage

    Less than Tip of drain hose 50mm gap dipped in water Water Water Water Waving leakage leakage leakage Ditch - 24 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 25: Forming The Piping

    3. Fix the piping onto the wall by saddle or equivalent. Trap - 25 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 26: Air Purging

    When the system pressure is reduced to normal, gauge disconnect the hose from the cylinder. Charge hose Outdoor unit Nitrogen gas cylinder(in vertical standing position) - 26 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 27: Finishing The Job

    This completes air purging with a vacuum pump. Vacuum pump The air conditioner is now ready to test run. - 27 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 28: Test Running

    The pressure of the gas side Refrigerant TEMP. service valve. R-22 35°C (95°F) 4~5kg/cm G(56.8~71.0 P.S.I.G.) R-410A 35°C (95°F) 8.5~9.5kg/cm G(120~135 P.S.I.G.) - 28 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 29: Pump Down

    Now Pump Down procedure is completed, and all refrigerant is collected into the outdoor unit. - 29 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 30: Functions

    Airflow Direction Control • The louver can be set at the desired position or swing Heater (Optional) up and down automatically. - 30 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 31 - 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. Discharge pipe temp. control Low ambient - 31 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 32 : 1, 2, 3, 4, 5, 6, 7, Off Timer Airflow Direction Control Power Save Cooling Button Horizontal Airflow Direction Control Button(Optional) Reset (Optional) Auto Clean AUTO CLEAN - 32 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 33: Operation

    (Cool, Heat) opeation operation dehumidifi- Standard Too hot Comfortable Cold Too cold mode cation Shape of Setting display temp. - 33 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 34 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. - 34 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 35: Cooling Mode Operation

    Model Step 1 Step 2 Step 3 Step 4 Step 5(Fc) Step 6 Step 7 AS-W1863_ Series AS-W2463_ Series - 35 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 36 • 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. - 36 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 37: Heating Mode Operation

    Model Step 1 Step 2 Step 3 Step 4 Step 5(Fc) Step 6 Step 7 AS-W1863_ Series AS-W2463_ Series - 37 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 38 18°C 18°C Fuzzy airflow 18~30°C Fuzzy rule during opertion below 18°C 18°C Fuzzy rule over 30°C 30°C Fuzzy rule - 38 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 39 18°C 18°C Fuzzy airflow 18~30°C Fuzzy rule during operation below 18°C 18°C Fuzzy rule over 30°C 30°C Fuzzy rule - 39 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 40: Jet Cool Mode Operation

    Mode 7 Mode 6 Mode 5 Mode 4 Mode 3 Mode 2 Chaos Swing Mode 1 The first path OPEN - 40 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 41: Sleep Timer Operation

    Heating OFF temp. (Setting temp. +4°C) 1.0°C down 1.0°C down Heating ON temp. (Setting temp. +2˚C) Sleep time ( hr ) - 41 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 42: Forced Operation

    - Indoor pan: Strong wind - COMP frequency: Step 5 - COMP compulsorily operates for about 18 minutes irrespective of indoor temperature. - 42 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 43: Protection From Total Current Control

    • If it’s 5 times within 1 hour in case of the temperature of outdoor pipe TH is over 65°C while the compressor is operating, the appliance turns off and display ERROR CODE 6. - 43 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 44: Portection From Overheating Of Power Module

    T3 = T2 + ∆T AS-W1863_ Series AS-W2463_ Series COMP Freq. Free Fc-1 Fc-2 Fc-2 Fc-1 Free Fh min - 44 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 45 Setting Open step 4-Way Setting Setting Speed Speed Outdoor Hi Speed Setting Speed Indoor Start Starting Pre-Heat Deice STEP - 45 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 46: Auto Cleaning

    Outdoor pipe temp. Outdoor fan On/Off control ° 0°C outdoor fan On/Off control °… Outdoor temp. - 0°C Time(Min.) - 46 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 47: Disassembly

    Inlet Grille assembly. 1. Before removing the control box, be sure to take out the wire screwed at the other end. - 47 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 48 4. To remove the Evaporator. • Remove 3 screws securing the evaporator(at the left 2EA in the Eva Holder, at the right 1EA). - 48 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 49 • Remove the left end of the cross-flow fan from the self-aligning bearing. - 49 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 50: Schematic Diagram

    LIMIT S/W-1 CONNECTOR FORCED PWB ASM OPERATON LIMIT S/W-2 CN-STEP1 CN-STEP2 TO OUTDOOR UNIT STEP STEP MOTOR-1 MOTOR-2 3854A20305H - 50 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 51: Wiring Diagram

    TERMINAL BLOCK 20A/AC 250V FUSE CN-U CN-V SPM2 COMP GN/YL CN-W WCN-NOISE 3(BK) Outdoor PWB ASSY WCN-NOISE 2(BK) 3854A20310C - 51 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 52: Components Location

    C 0 5 D C 0 7 D I C 0 2 D J P 2 J 0 1 - 52 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 53 Schematic Diagram INDOOR MAIN P.W.B ASSEMBLY(AS-W2463_Series) • TOP VIEW • BOTTOM VIEW - 53 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 54 S c a n 3 S c a n 4 S c a n 5 V c c G N D - 54 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 55 Schematic Diagram OUTDOOR MAIN P.W.B ASSEMBLY(AS-W1863_Series/AS-W2463_Series) • TOP VIEW • BOTTOM VIEW - 55 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 56: Troubleshooting Guide

    3-WAY VALVE HEAT HEAT EXCHANGE EXCHANGE (EVAPORATOR) (CONDENSER) GAS SIDE REVERSING 3-WAY VALVE ACCUMU VALVE LATOR COOLING COMPRESSOR HEATING - 56 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 57: Pipe Length And The Elevation

    CAUTION:* Capicity is based on standard length and maximum allowance length is the basis of reliability. * Oil trap should be installed per 5~7 meters. - 57 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 58: 2-Way, 3-Way Valve

    Open Pressure check (with charging cylinder) Open Open (Servicing) Open Gas releasing (with charging cylinder) Open Open (Servicing) - 58 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 59 (5) Use torque wrench to tighten the service port nut to a torque of 1.8kg.cm. a gas cylinder. - 59 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 60: Pumping Down

    – Open the low-pressure valve on the charge set slightly to air purge from the charge hose. (5) Set the 2-way valve to the closed position. - 60 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 61 – Close the valve on the gas cylinder and dis- charge the refrigerant until the gauge indicates 3 to 5 kg/cm - 61 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 62 – Discharge the refrigerant gradually; if it is dis- charged too suddenly, the refrigeration oil will also be discharged. - 62 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 63 (4) Disconnect the charge hose from the vacuum pump. – Vacuum pump oil. If the vacuum pump oil becomes dirty or depleted, replenish as needed. - 63 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 64: Gas Charging

    1 minute and then repeat the procedure (pumping down-pin). - 64 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 65: Cycle Parts

    2. The temperature can be measured by attaching the thermometer to the low pressure tubing and wrap it with putty. - 65 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 66: Self-Diagnosis Function

    D-PIPE TH is short or open. The LED01M will be blinking 10 (restart compressor when D-PIPE TH. is times. recovered) - 66 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 67 • Check the condition of connectors • The condition of P.C.B pattern. • The condition of P.C.B pattern. • The electronic components. - 67 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 68: Electronic Parts

    4) Replace P.C.B Ass'y 5) IC01A(KIA7036) 5) The voltage of micom pin 19 5) Replace P.C.B Ass'y : DC4.5V↑ - 68 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 69 : DC +5V Check point • Check the connecting circuit between MICOM PIN and CN-DISP1 PIN • Check receiver ass'y - 69 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 70 Check the electrical wiring diagram of Outdoor side. Check the open or short of connecting wires between Indoor and Outdoor. - 70 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 71 The voltage of Pin No 1(orange) and 3(black) of CN-MOTOR. About AC 180V over About AC 50V over SSR is not damaged Check SSR - 71 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 72 If there are no problems after above checks. • Confirm the assembly condition that are catching and interfering parts in the link of the vertical louver - 72 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 73 • 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). - 73 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 74 PCB Ass'y about AC220V / 240V when Operation's ON? Is the Bridge Diode(BD01S) right? Check the Bring Diode. Replace the PCB Ass'y. - 74 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 75 Supply the refrigerant or Discharge refriger- Is the refrigerant pressure right? ant. Replace the PCB Ass'y. • Main PCB Ass'y • Control Box Ass'y - 75 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 76 CN-AC/DC indoor P.C.B Ass'y is right? • Check the PCB pattern(Resoldering). Replace the PCB Ass'y. • Main PCB Ass'y (Indoor/Outdoor) • Control Box Ass'y. - 76 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 77 Supply the refrigerant or Discharge the Is the refrigerant pressure right? refrigerant. Replace the PCB Ass'y. • Main PCB Ass'y(Outdoor) • Control Box Ass'y(Outdoor) - 77 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 78 (when the discharge pipe TH opens) • Stop Comp. operation (when the discharge pipe TH shorts) OPEN • Stop compressor. CN-UVW - 78 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 79: Exploded View

    249951 352115 266090 352116 264100 145200C 147582A W0FZZ 35211B 145200D 567480 W50400 146811A 435301 147581 W6640 135311 135516 268711B - 79 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 80: Outdoor Unit

    435512 552202 Discharge Thermistor 561410 W6631 447910 554160 552203A 550140 430410 152503 349480 552112 435301 W49810 552203B 237202 437211 - 80 - Copyright ©2009 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 81 P/No.: 3828A20195V October. 2009...

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