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LG AP-Z Series Service Manual

Floor standing type air conditioner
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LG

Floor Standing Type

Air Conditioner

SERVICE MANUAL
MODEL: AP-Z Series
website http://www.lgservice.com
e-mail http://www.lgeservice.com/techsup.html
CAUTION
• BEFORE SERVICING THE UNIT, READ THE SAFETY
PRECAUTIONS IN THIS MANUAL.
• ONLY FOR AUTHORIZED SERVICE PERSONNEL.
LG

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Summary of Contents for LG AP-Z Series

  • Page 1: Floor Standing Type

    Floor Standing Type Air Conditioner SERVICE MANUAL MODEL: AP-Z Series CAUTION • BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. • ONLY FOR AUTHORIZED SERVICE PERSONNEL.

  • Page 2: Table Of Contents

    Floor Standing Type Air Conditioner Service Manual TABLE OF CONTENTS Safety Precautions............................3 Functions ..............................7 Product Specifications ...........................10 Wiring Diagram............................12 Operation Details ............................16 Installation of Indoor, Outdoor Unit.......................23 Test running.............................29 3-way valve ..............................31 Cycle Troubleshooting Guide .......................37 Electronic Parts Troubleshooting Guide....................38 Exploded View and Replacement Parts List ..................41 2 Floor Standing Type Air Conditioner...

  • Page 3: Safety Precautions

    Safety Precautions Safety Precautions To prevent injury to the user or other people and property damage, the following instructions must be followed. I 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.
  • Page 4 Safety Precautions Do not install, remove, or re- Be cautious when unpacking For installation, always con- install the unit by yourself and installing the product. tact the dealer or an Autho- (customer). rized Service Center. • There is risk of fire, electric shock, •...
  • Page 5 Safety Precautions Do not store or use flammable gas or com- If strange sounds, or small or smoke comes bustibles near the product. from product. Turn the breaker off or discon- nect the power supply cable. • There is risk of fire or failure of product. •...
  • Page 6 Safety Precautions Keep level even when installing the product. Use two or more people to lift and transport the product. • To avoid vibration or water leakage. • Avoid personal injury. 90˚ I Operational Use a soft cloth to clean. Do not use harsh Do not touch the metal parts of the product detergents, solvents, etc.

  • Page 7: Functions

    Functions Functions Indoor Unit Power Switch ON/OFF Operation Mode Control • Cooling, Heating, Soft Dry, Fan Indoor Fan Speed Control • High, Low Jet Cool or Turbo -Z (AP-Z286R Model only) • Speed Cooling operates super high fan speed in cooling mode Energy Saving (AP-Z286R Model only) •...

  • Page 8: Remote Control

    Functions Remote Control Operation ON/OFF Cooling Operation Mode Heating Operation Mode Sot Dry Operation Mode • Intermittent operation of fan at low speed. Fan Operation • Used to circulate room air without cooling. Timer Control • OFF Timer (1, 2, 3,..7 hour) Jet Cool or Turbo-Jet •...
  • Page 9 Functions Outdoor Unit Deice Control • De-ice PCB Outdoor Fan Speed Control • One speed Sensing Heat Exchanger Temperature • Heat exchanger temperature sensor (Thermistor) Service Manual 9...

  • Page 10: Product Specifications

    48,000 88,000 Heating Power Input 2,800 5,000 8,200 Current 14.5 Model 5JS330DJSA008 AR061YAB AR061YAB + AQ042YAB Maker Matsushita Ele. LG Ele. LG Ele. Type Rotary Scroll Scroll Compressor Capacity Btu/h 28,101 50,800 50,800 + 35,200 Input 2,915 5,347 5,347 + 3,608...

  • Page 11: Indoor Unit

    Product Specifications I AP-Z286RC0, AP-Z286R20, AP-Z286R30 Indoor Unit Outdoor Unit Top/Bottom Airflow Controller Left/Right Airflow Controller Cool air outlet(2 sides) by Manual operation Cool air outlet(front side) Top/Bottom Airflow Controller Control Cover Left/Right Airflow Controller Control Panel Air Inlet(back side) Sliding Clean Door Remote Controller Holder Display Panel...

  • Page 12: Wiring Diagram

    Wiring Diagram I AP-Z728FA0 Indoor Unit Outdoor Unit Air Outlet Vent Air Outlet Vent Air Intake Vent (Rear) Air Intake Vent Wiring Diagram (1) AP-Z286RC0, AP-Z286R20, AP-Z286R30 I INDOOR *AP-Z286RC0 GN/YL DOOR DOOR T/B2 S/W1 S/W1 REVERSING A/CL VALVE UNIT MAIN (AC) PCB ASM C TH Deice PCB...
  • Page 13 Wiring Diagram I INDOOR *AP-Z286R20, AP-Z286R30 I OUTDOOR *AP-Z286RC0, AP-Z286R20, AP-Z286R30 Service Manual 13...

  • Page 14: Outdoor Unit Wiring Diagram

    Wiring Diagram (2) AP-Z488TC0 GN/YL INDOOR ELECTRIC CIRCUIT AC PCB ASM INDOOR CAPACITOR MOTOR CN-OUTUNIT CN-FAN DOOR S/W FUSE GN/YL 250V RY-COMP 3.15A CN-AIRC RY-4WAY RY-HIGH HEAT PCB ASM DOOR S/W RY-MID CN-HEAT RY-LOW HEAT CLEANER RY-SYNC (AIR CLEANER MODEL ONLY) PIPE SYN.
  • Page 15 Wiring Diagram (3) AP-Z728FA0 INDOOR UNIT CIRCUIT DIAGRAM MAIN PCB ASM INDOOR FAN MOTOR ROOM PIPE FUSE (10A) SUB PCB ASM CONNECT TO OUTDOOR (HOUSING ASM) ELECTRIC HEATER PART CONNECT TO CONTACT "T" "N" OF OUTDOOR TERMINAL BLOCK "TM" P/NO: 3854A20410C PIPE TH THERMISTER FOR EVA TEMP.

  • Page 16: Operation Details

    Operation Details Operation Details (1) The function of main control 1. Time Delay Safety Control 3min The compressor is ceased for 3 minutes to balance the pressure in the refrigeration cycle. (Protection of compressor) 3sec The indoor fan is ceased for 3 seconds to prevent relay noise. (Protection of fan relay and micro chip) 30sec The 4-way valve is ceased for 30 sec.

  • Page 17: Heating Mode Operation

    Operation Details 5. Heating Mode Operation The unit will operate according to the setting by the remote controller and the operation diagram is shown as following. Intake Air Temp. Setting Temp. +1°C (Compressor OFF) Setting Temp. (Compressor ON) Setting Temp. -1°C minimum minimum minimum...
  • Page 18 Operation Details 5-1. Heating Mode Operation The unit will operate according to the setting by the remote controller and the operation diagram is shown as following. Intake Air Temp. Setting Temp. +1°C (Compressor OFF) Setting Temp. (Compressor ON) Setting Temp. -1°C minimum minimum 10sec.
  • Page 19 Operation Details 6. Hot-Start Control • The indoor fan stops until the evaporator piping temperature will be reached to 28°C. • During heating operation, if piping temperatures fall below 26°C fan stops. • The operation diagram is as following. Maximum 1min INDOOR PIPE TEMP.
  • Page 20 Operation Details 8. Soft Dry Operation Mode • During Soft Dry Operation, the compressor ON temperature is the setting temperature plus 2°C, the compressor OFF temperature is the setting temperature minus 1°C. • When the room temperature rises over the compressor ON temperature, the operation mode is switched to the Cool- ing mode.
  • Page 21 Operation Details 12. Alarm mode display / only displayed while operating. CO : The sensor for sensing room temperature is open or short. C1 : The sensor for sensing piping temperature is open or short. 13. Jet Cool or Turbo-Jet ❏...
  • Page 22 Operation Details 16. Function of changing set temperature when re-operation after stop. Operation is set the following condition when re-operation with start/stop button. 1.Operation mode. Cooling/soft dry mode Cooling mode Heating mode Heating mode 2. Setting the set temperature when cooling operation. Room temperature >...

  • Page 23: Installation Of Indoor, Outdoor Unit

    Installation of Indoor, Outdoor Unit Installation of Indoor, Outdoor Unit 1. Selection of the best location 1) Indoor unit • There should not be any heat source or steam near the unit. • There should not be any obstacles to prevent the 40cm air circulation.

  • Page 24: Indoor Unit Installation

    Installation of Indoor, Outdoor Unit 2. Indoor Unit installation 3. Outdoor unit Installation The mounting floor should be strong and solid Install the outdoor unit on the concrete or any enough to prevent it from vibration. solid base securely and horizontally by securing it with bolts (Ø12mm) and nuts.

  • Page 25: Installation Method

    Installation of Indoor, Outdoor Unit Installation Method 1. Procedure Installation works Descriptions Preparation of tools and installation parts Preparation of installation Flaring the pipes To insert the flare nuts, mounted on the connection parts of both indoor and outdoor unit, onto the copper pipes. Pipe bending To reduce the flow resistance of refrigerant.

  • Page 26: Preparation Of Installation Parts And Tools

    Installation of Indoor, Outdoor Unit 2. Preparation of installation parts and tools Installation Parts, Tools Flaring toolFlaring the pipes Remear Remove burrs from cut edges of pipes. Pipe cutter (MAX 35mm Copper pipe) Cutting the pipings Wrench (H5, H4 hexagonal wrench) To open the service valve Pipe bender Bending the pipings...

  • Page 27: Preparation Of Piping

    Installation of Indoor, Outdoor Unit Piping of Indoor Unit 1. Preparation of piping Pipe cutter Cut the pipes and the cable • Use the accessory piping kit or the pipes purchased locally. Slanted Rough • Measure the distance between the indoor and 90°...

  • Page 28: Connection Of Piping

    Installation of Indoor, Outdoor Unit 2. Connection of piping Move the indoor tubing and drain hose to the hole • Remove tubing holder and pull the tubing out of the chassis. Replace the tubing holder into original position Route the tubing and the drain hose staight backwards. Insert the connecting cable into the indoor unit through the hole.

  • Page 29: Test Running

    Test running Test running 1. PRECAUTIONS IN TEST RUN • The initial power supply must provide at least 90% of the rated voltage. Otherwise, the air conditioner should not be operated. Carry out the test run more than 5 minutes without fail. Caution (Test run will be cancelled 18 minutes later automatically) •...

  • Page 30: Hand Over

    Test running CAUTION After the confirmation of the above conditions, prepare the wiring as follows: 1) Never fail to have an individual power specialized for the air conditioner. As for the method of wiring, be guided by the circuit diagram pasted on the inside of control box cover. 2) Provide a circuit breaker switch between power source and the unit.

  • Page 31: 3-Way Valve

    3-way valve 3-way valve 1. Pump down Liquid side Indoor unit Open Outdoor unit 3-Way valve Gas side Closed 3-Way valve CLOSE CLOSE Purge the air • Procedure (6) Operate the air conditioner in cooling mode (1) Confirm that both liquid side and gas side and stop it when the gaug e indicates valves are set to the open position.
  • Page 32 3-way valve 1) Re-airpurging (Re-installation) Liquid side Indoor unit Closed Outdoor unit 3-Way valve Gas side Closed 3-Way valve Gas cylinder OPEN CLOSE • Procedure (6) Disconnect the charge set and the gas cylin- (1) Confirm that both the liquid side valve and the der, and set the 2-way and 3-way valves to the gas side valve are set to the closed position.
  • Page 33 3-way valve 2) 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 OPEN CLOSE • Procedure (1) Confirm that both the liquid side and gas side (3) Open the valve (Lo side) on the charge set valves are set to the back seat.
  • Page 34 3-way valve 2. Evacuation (All amount of refrigerant leaked) Liquid side Indoor unit Outdoor unit 3-Way valve Open Gas side 3-Way valve Open Vacuum pump OPEN CLOSE • Procedure (1) Connect the vacuum pump to the center hose (3) Close the valve (Lo side) on the charge set, of charge set center hose turn off the vacuum pump, and confirm that the gauge needle does not move (approxima-...

  • Page 35: Gas Charging

    3-way valve 3. Gas Charging (After Evacuation) Liquid side Indoor unit Open Outdoor unit 3-Way valve Gas side Open 3-Way valve Check valve Charging cylinder OPEN CLOSE • Procedure (1) Connect the charge hose to the charging This is different from previous procedures. cylinder.
  • Page 36 3-way valve 2) Heating Mode (After Evacuation) Charging cylinder OPEN CLOSE Check valve Liquid side Indoor unit Open Outdoor unit 3-Way valve Gas side Open 3-Way valve • Procedure (1) Connect the charge hose to the charge cylinder. • Connect the charge hose which you disconnected This is different from previous procedures.

  • Page 37: Cycle Troubleshooting Guide

    Cycle Troubleshooting Guide Cycle Troubleshooting Guide Trouble analysis 1. Check temperature difference between intake and discharge air and operating current. Temp. difference : approx. 0°C All amount of refrigerant leaked out Current : less than 80% of Check refrigeration cycle rated current Temp.

  • Page 38: Electronic Parts Troubleshooting Guide

    Electronic Parts Troubleshooting Guide Electronic Parts Troubleshooting Guide 1) No Cooling operation performed Possible Trouble 1 : The unit does not operate. Check the FUSE Is the input voltage and the wiring diagram. of transformer AC220V? Is the output voltage Is shorted the Check the main P.C.B of transformer about AC14V?
  • Page 39 Electronic Parts Troubleshooting Guide 2) No heating operation works Is the AC220V (AC 240 V) between connector (CN-outunit) and of Main P.C.B Is the input power AC220V (AC240V) at COMP magnetic coil contactor? Is the unit operating? Check the wiring Check the COMP magnetic connection contactor of outdoor unit.
  • Page 40 Electronic Parts Troubleshooting Guide 3) No heater operation works Select the heating operation mode. Is the heating operating? Is the Compressor Compressor "ON" operating? Is the Heat S/W of Main Heat S/W "ON" PCB "ON"? Is the heater S/W of Main Heater S/W "ON"...

  • Page 41: Exploded View And Replacement Parts List

    Exploded View and Replacement Parts List Exploded View and Replacement Parts List I AP-Z286RC0, AP-Z286R20, AP-Z286R30 1. Indoor Unit 146811-1 137211 235811-1 146811-2 132111 146811-3 135310 135511 235512 235811-2 249941 267110 W0CZZ 268711-3 135313-2 268711-4 268711-2 237201 135313-1 Service Manual 41...
  • Page 42 Exploded View and Replacement Parts List W52103 W4811-2 354212 W4810-2 354210 W4811-1 135515 567480 753000 35211A 35211C 753010 130911 336610 266000 336600 352150 W4810-1 349480 337000 159830 W50400 346810 140570 359012 W1WE W1NF 730700 42 Floor Standing Type Air Conditioner...
  • Page 43 Exploded View and Replacement Parts List Parts List (Indoor Unit ) PART No. LOCATION DESCRIPTION Q'TY Remark AP-Z286RC0 AP-Z286R20 AP-Z286R30 130911 CABINET ASSEMBLY,INDOOR 3091A10037E 3091A10037Y 3091A10037S 132111 FRAME ASSEMBLY 3211A20006C 135310 GRILLE ASSEMBLY DIFFUSER(INDOOR) 3531A10133N 3531A20164D 3531A20164F 135511 COVER ASSEMBLY, CONTROL(INDOOR) 3551A20053C 135313-1 GRILLE ASSEMBLY,INLET...

  • Page 44: Outdoor

    Exploded View and Replacement Parts List 2. Outdoor Unit 44 Floor Standing Type Air Conditioner...

  • Page 45: Service Manual

    Exploded View and Replacement Parts List Parts List (Outdoor Unit ) PART No. LOCATION DESCRIPTION Q'TY Remark AP-Z286RC0/R20/R30 137213-1 PANEL ASSEMBLY,SIDE 1A00202F 137213-2 PANEL ASSY,SIDE 3A02284L 268711 PWB(PCB) ASSY,DEICER 6871A20015Z W6920 RELAY 6920AP3400A 349480 ORIFICE 4948AP2527A 349600 MOUNT,MOTOR 1A00206B 430411 BASE ASSEMBLY,WELD[OUTDOOR] 3041A20022G 435301...
  • Page 46 Exploded View and Replacement Parts List I AP-Z488TC0 1. Indoor Unit 135310 753000 267110 146812 753010 137211 268714 W4811 668713 W4810 354210 237202 354210 W4810 330870 152302 135313 46 Floor Standing Type Air Conditioner...
  • Page 47 Exploded View and Replacement Parts List 135515 249951 249941 268715 W4810 135500 130900 W0CZZ W50400 359012 336610 346810 349480 W4810 135317 150170 349600 130400 Service Manual 47...
  • Page 48 Exploded View and Replacement Parts List Parts List (Indoor Unit ) LOCATION DESCRIPTION PART No. Q'TY Remark 130400 BASE,INDOOR 3040AP2199D 130900 CABINET 3090AP1174D 135310 GRILLE ASSEMBLY,DIFFUSER(INDOOR) 3531A20099H 135313 GRILLE ASSEMBLY,INLET 3531A10126D 135317 GRILLE ASSEMBLY,INDOOR MOTOR 3531A20082A 135511 COVER 3550A10034A 135515 COVER ASSEMBLY,TOP(INDOOR) 3551A10013C 137211...
  • Page 49 Exploded View and Replacement Parts List 2. Outdoor Unit Service Manual 49...
  • Page 50 Exploded View and Replacement Parts List Parts List (Outdoor Unit ) LOCATION DESCRIPTION PART No. Q'TY Remark 135301 GRILLE,DISCHARGE 3530AP1225D 137213 PANEL ASSEMBLY,SIDE 3721A20229A 147780 3A02521A 150400 RUBBER 5040AP3178A 268711 PWB(PCB) ASSY,DEICER 6871A20034A 430410 BASE ASSEMBLY,WELD[OUTDOOR] 3041A20047B 435511 COVER ASSY,CONTROL(OUTDOOR) 3A01293X 435512 COVER ASSY,TOP(OUTDOOR)
  • Page 51 Exploded View and Replacement Parts List I AP-Z728FA0 1. Indoor Unit 437210 135310 235450 268711-1 237202 336610 147911 359012 330720 W0CZZ 159830 648600 249941 135313 268711-2 268711-4 135313 Service Manual 51...
  • Page 52 Exploded View and Replacement Parts List 753010 346810 150170 352114 354210 W4810-2 W4810-1 330870 52 Floor Standing Type Air Conditioner...
  • Page 53 Exploded View and Replacement Parts List Parts List (Indoor Unit ) LOCATION DESCRIPTION PART No. Q'TY Remark 135310 GRILLE ASSEMBLY,DIFFUSER(INDOOR) 3531A20105B 135313 GRILLE ASSEMBLY,INLET 3530AP1109A 135313 GRILLE ASSY,INLET 5237AP2386A 147911 BARRIER ASSEMBLY,INDOOR 4791AP2300D 150170 MAGNET ASSEMBLY,MECH 3A02221A 159830 FILTER ASSY,A/C 5231AP3330A 235450 DISPLAY ASSEMBLY (MECH)
  • Page 54 Exploded View and Replacement Parts List 2. Outdoor Unit 54 Floor Standing Type Air Conditioner...
  • Page 55 Exploded View and Replacement Parts List Parts List (Outdoor Unit ) LOCATION DESCRIPTION PART No. Q'TY Remark 268711 PWB(PCB) ASSY,DEICER 6871A20015S 346811 MOTOR ASSEMBLY,OUTDOOR 4680AP2610B 349490 ORIFICE 4948AP1242R 430411 BASE ASSEMBLY,WELD[OUTDOOR] 3041A10037D 435301 GRILLE ASSY,DISCHARGE(OUTDOOR) 2A00144P 437210 PANEL ASSY,FRONT SUB 3721AP2913P 437210 PANEL ASSY,FRONT SUB...
  • Page 56 March, 2006 Printed in Korea P/No.: 3828A20156G...

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