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LG AH-W096A0 Service Manual
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LG AH-W096A0 Service Manual

LG AH-W096A0 Service Manual

Lg thermav system ah series air conditioners
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Internal Use Only
http://biz.lgservice.com
System
SVC MANUAL
MODEL: AH 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 AH-W096A0

  • Page 1 Internal Use Only http://biz.lgservice.com System SVC MANUAL MODEL: AH Series CAUTION Before servicing the unit, read the safety precautions in general SVC manual. Only for authorized service personnel.

  • Page 2: Table Of Contents

    1. Checking Key Components of Indoor Unit 2. Checking Key Components of Outdoor Unit 3. Self-Diagnosis Feature 4. Trouble Shooting Guide - 2 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 3: Safety Precaution

    • Improper wiring or installation • There is risk of fire or electric shock. may cause fire or electric shock - 3 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 4 • There is risk of fire or electric • There is risk of fire or electric shock. shock. shock. - 4 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 5 • There is risk of fire or electric • There is risk of electric shock. • This could result in personal shock. injury and product damage. - 5 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 6 • It may cause a problem for your neighbors. • Avoid personal injury. - 6 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 7 Use a firm stool or ladder when cleaning or maintaining the prod- uct. • Be careful and avoid personal injury. - 7 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 8: General Information

    2.2 Outdoor Unit ............13 3. Combination of Outdoor Units ........14 4. Nomenclature..............15 4.1 Indoor Unit .............15 4.2 Outdoor Unit ............15 - 8 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 9: Model Information

    *2 : tested under Eurovent Cooling condition (water temperature 23°C ¡ 18°C at outdoor ambient temperature 35°C / 24°C) - 9 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 10 2. * : This information is given as a guideline about the connection of for purpose of improvement. sanitary water tank - 10 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 11: Lge Internal Use Only

    2. Wiring cable size must comply with the applicable local and national code. 3. The specification may be subject to change without prior notice for purpose of improvement. - 11 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 12: External Appearance

    External Apprearance 2. External Apprearance 2.1 Outdoor Unit AH-W096A0. AH-W126A0, AH-W146A0, AH-W166A0 2.2 Indoor Unit - 12 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 13: Part 2 : Features & Controls

    Part 2 Features & Controls - 13 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 14: List Of Function

    * TH8 : Refer to 'Chapter 8. Piping Diagram' of 'Part 2. Indoor Unit (Hydro kit)' * Accessory: Installed at field, ordered and purchased separately by the corresponding model mane, supplied with separate package. - 14 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 15: Features

    Outlet water temp. Hot water temp. Indoor temp. Solar source temp. Indoor temp. or Water temp. (Optional temp. setting) - 15 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 16: Controller Configuration

    Silent Mode ON / OFF Slight Trouble Thermostat Water Tank Temp. Heavy Trouble Electric Heater (1) Solar Heating Temp. - 16 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 17: Special Function

    . To release this setting, pressing function Setting button until icon flash and then enter setting/clear button. - 17 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 18: Sleep Timer Operation

    Operation Time Table (Example) Setting Temp. 25°C 25°C 25°C 25°C 25°C 09:00 08:00 09:00 08:00 09:00 12:00 17:00 12:00 12:00 12:00 - 18 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 19: Dip Switch Setting

    • Whenever adjusting DIP switch, turn off electric power supply to avoid electric shock. General Information OFF is selected ON is selected - 19 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 20 2kW for AH-W096A0) heater capacity Electric heater is not used Thermostat is NOT installed Thermostat installation information Thermostat is installed - 20 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 21: Control Panel Setting

    • Function Code 07 : Address Setting When Central Controller is installed, address assigning is set by this function. - 21 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 22: Temperature Range Setting

    • Sanitary water tank and sanitary water tank kit should be installed. • DIP switch No. 2 and 3 should be set properly. - 22 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 23: Temperature Control Parameter Setting And Etc

    • If Value #2 is set as ’00’ but FCU or 2way valve is NOT installed, the product can abnormal operation. Function Code 23 and 24 : Setting Weather-dependent operation Mode - 23 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 24 Function Code 24 or 25 Outdoor Value #1 of Value #2 of air temperature Function Code 23 Function Code 23 - 24 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 25 • To use disinfection mode, sanitary water heating should be <Sanitary Water Heating Disable> enable. <Sanitary Water Heating enable> - 25 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 26: Control Logic

    If Value #1 is set as ‘1’, then electric heater is never turned on and only water heater is on and off according to control logic. - 26 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 27: Control Logic

    5. Input Current Control .......................35 6. Outdoor Fan Control ......................37 7. Defrost Control .........................38 8. EEV Control........................39 9. Heat sink control ......................41 - 27 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 28: Compressor

    Frequency ¡ Number of poles BLDC Motor IPM (Inverter) U V W X Y Z Position Detect (16Bits) Circuit - 28 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 29 • Step E = (Step D + Target Frequency) / 2 Target frequency (Hz) Step E frequency Step D Step C Step B Step A Time (sec) - 29 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 30: Step(Frequency) Control

    ✽ The compressor get the minimum step in case Step base value is lower than the minimum step of operating capacity. - 30 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 31 Working ratio 100% Temp.(°C) ∆Step DTW : Step Compensation of temperature difference between Inlet water temp. and setting temp. - 31 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 32 Working ratio 113% 100% Temp.(°C) ∆Step DTW: Step Compensation of temperature difference between Inlet water temp. and setting temp. - 32 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 33: Reversing Valve Operation

    7. If the compressor is stopped during heating mode by Thermistor signal, reversing valve will remain in heating position. - 33 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 34: Discharge Pipe Temperature Control

    Down Down ß‚ Pulse Up Stop control Expansion valve °C Model Toff EEV ß‚ pulse AHUW166A0 95°C 105°C - 34 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 35: Input Current Control

    Frequency [Hz] Down Down Cooling Heating Cooling & Frequency Model Down Heating (CT 1) (CT 1) (CT 2) AHUW166A0 - 35 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 36 Base Step-6 0~4°C Base Step+1 9~14°C Base Step-7 -4~0°C Base Step+2 2~9°C Base Step-8 -8~-4°C Base Step+3 -3~2°C Base Step-9 - 36 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 37: Outdoor Fan Control

    T pipe (Cond Out) T2 ˚C T1 ˚C Outdoor fan Setting value Setting value T1°C T2°C Model 6°C 11°C AHUW166A0 - 37 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 38: Defrost Control

    Bypass valve start Indoor Fan Fan ON when pipe temperature above 25°C(option) ON/OFF Outdoor Fan Maximum flow Setting flow - 38 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 39: Eev Control

    Comp Comp Comp Power input (Reset) Heating: Cooling: Open Close -200 Starting Initializin Time constant control 90sec control - 39 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 40 0.8 x Target Pulse 0.7 x Target Pulse(Cooling) Comp starting Time(Option) Time 30sec 150sec 270 sec 300 sec 330 sec - 40 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 41: Heat Sink Control

    Heat Sink temp Toff °C T2 °C T1 °C COMP Hz Frequency Frequency frequency frequency fixed fixed Down Down - 41 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 42: Test Run

    2.0 MΩ as a result of refrigerant accumulation in the internal compressor. If the insulation resistance is less than 2.0 MΩ, turn on the main power supply. - 42 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 43: Test Run Flow Chart

    (comp.,Fan, others ) to Heating mode Refer to Troubleshooting Is hot water discharged ? After Hot Start Guide Normal - 43 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 44: Part 3 Replacement

    Part 3 Replacement - 44 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 45: Replacement Procedure For Compressor

    If recovery unit is used, charge refrigerant. When inserting the sound proof, be sure to insert counter-clockwise. <Figure 2> Suction pipe Discharge pipe - 45 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 46: Replacement Procedure For Inv Pcb

    Confirm that there is no gap between INV PCB case and control case.(Figure 4.) If any gap is present, it will cause product malfunction. - 46 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 47: Caution For Assembling Outdoor Panels After Test Run

    If screws are not assembled, it allows rain come into control box causing defect of unit. - 47 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 48: Part 4 : Trouble Shooting

    Part 4 Trouble Shooting - 48 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 49 3.2 Error Code List..................60 4. Trouble Shooting Guide ..............62 3.1 Concept of ‘Classified Trouble’ ...............63 3.1 Concept of ‘Classified Trouble’ ...............64 - 49 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 50: Checking Key Components Of Indoor Unit

    • Also, check the water quality if there are particles that can yield locking at the shaft of the water pump. - 50 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 51: Water Pump

    PCB is in trouble. In this case, contact official After Service Center and replace the indoor unit PCB. • To correct wrong wiring, please refer - 51 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 52: Electric Heater

    If the reason of malfunction is clearly proved as the defect of the electric heater itself, then replace it with new one. - 52 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 53: Control Panel

    Unless 2nd and 3rd pin of DIP switch setting is 01(OFF-ON) or 10(ON-OFF), the water tank heating will not be configured. - 53 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 54: Checking Key Components Of Outdoor Unit

    (when measuring absolute values). Accurate measuring values cannot be obtained with a general portaable tester (For analog and digital mode). - 54 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 55: Fan Motor

    3. If problems continue to occur even after counter- measure of No.1 and No.2, it means that both boards has defect. - 55 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 56: Electronic Expansion Valve

    Full open EEV noise. open 1350 pulses - If liquid refrigerant is in EEV, the noise is lower. pulse - 56 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 57 When the coil part is removed or assembled, be careful not to bend the pipe of the body. A part - 57 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 58: Indoor Unit

    If estimated temperature is very low in comparison with suction temperature which is displayed at remote controller then the valve is not fully closed - 58 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 59: Self-Diagnosis Feature

    - But in emergency operation, automatic re-start is prohibited to protect the product. - Therefore, user must restart the product after power reset when emergency operation has been running. - 59 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 60: Error Code List

    Slight / Heavy / Option Troubles : lowercases ‘ch’ + code no. - Errors : capital letters ‘CH’ + code no. - 60 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 61 Before conducting a checking or repairing job, pull out the plug out of the outlet and make sure that the lamp on the control board outdoor unit is off. - 61 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 62: Trouble Shooting Guide

    Change the sensor of sensor normal? Change the PCB Unplugged Plugged Ω 2.5Vdc Ω Check the resistance Check the voltage - 62 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 63: Concept Of 'Classified Trouble

    ‘entering Installer Setting Mode’ at the control panel. If not, system will NOT be operated correctly. It is STRONGLY recommended to keep above instruction. - 63 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...

  • Page 64: Concept Of 'Classified Trouble

    Indoor PCB fault Replace after checking ❊ CH05 is displayed at indoor unit, CH53 is displayed at outdoor unit. - 64 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 65 • This error can not be permitted damage a the EEPROM I Error diagnosis and countermeasure flow chart - Replace the indoor unit PCB - 65 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 66 • Also, check the water quality if there are particles that can yield locking at the shaft of the water pump. - 66 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 67 • Wait while room air is heated by target Leaving temperature of thermostat. water temperature is higher than 62 °C - 67 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 68 DC540V ¡¾ 10% DC680V ¡¾ 10% AUUW488D DC540V ¡¾ 10% DC680V ¡¾ 10% AUUW608D DC540V ¡¾ 10% DC680V ¡¾ 10% - 68 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 69 DC540V ¡¾ 10% DC680V ¡¾ 10% AUUW488D DC540V ¡¾ 10% DC680V ¡¾ 10% AUUW608D DC540V ¡¾ 10% DC680V ¡¾ 10% - 69 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 70 DC540V ¡¾ 10% DC680V ¡¾ 10% AUUW488D DC540V ¡¾ 10% DC680V ¡¾ 10% AUUW608D DC540V ¡¾ 10% DC680V ¡¾ 10% - 70 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 71 Check Pressure of suction pipe Check Pressure of discharge pipe Is it normal ? Re-vaccuming system & Re-charging Change main PCB - 71 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 72 DC540V ¡¾ 10% DC680V ¡¾ 10% AUUW488D DC540V ¡¾ 10% DC680V ¡¾ 10% AUUW608D DC540V ¡¾ 10% DC680V ¡¾ 10% - 72 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 73 Check inverter PCB assembly IPM normality Is inverter PCB assembly ¡ Replace inverter PCB assembly normal? Recheck power and installation condition - 73 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 74 Upgrade Micom Program S/W Program normal? Replace inverter PCB assembly Is Inverter PCB assembly normal? Recheck power and installation condition - 74 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 75 Is it normal (4.0Vdc )? Change Main PCB Check Check TRANS Is it normal? Change TRANS Change main PCB - 75 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 76 Correct connection 4.5Vdc at 25˚C Change the sensor Repair or Change the PCB. Estimate the resistance of each sensor. - 76 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 77 /5kΩ at 25˚C? Change the sensor Ω Plug the sensor on Indoor unit PCB Check the resistance Check the voltage - 77 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 78 Check PCB Check Flow Chart (CH60) Check the the connection port. Is it normal ? Correct connection Change EEPROM - 78 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 79 Replace inverter compressor PCB Check Point - Check the Transmission connector and LED (Main & Inverter) 42/48/60k <Inverter PCB> <MAIN PCB> - 79 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 80 Correct connection 2.5Vdc at 25˚C Change the sensor Repair or Change the PCB. Estimate the resistance of each sensor. - 80 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 81 Correct connection Or re-soldering PCB Check the DC Motor signal Is it normal ? Change Indoor Motor Repair or Change the PCB. - 81 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 82 Is inverter PCB assembly Check inverter PCB assembly IPM normality normal? ¡ Replace inverter PCB assembly Recheck power and installation condition - 82 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 83 0.542 0.63 0.459 1.25 0.469 0.54 0.397 1.07 0.406 0.46 0.345 0.92 0.353 0.79 0.307 0.34 0.262 0.68 0.268 - 83 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 84 18.89 2.561 1.26 2.28 14.79 2.255 1.07 2.09 11.72 1.972 0.92 1.716 1.73 7.62 1.487 0.69 1.57 6.24 1.287 - 84 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 85 0.44 3 Phase AUUW368D 1.84 1.84 1.84 AUUW428D 1.08 1.08 1.08 AUUW488D 1.08 1.08 1.08 AUUW608D 1.08 1.08 1.08 - 85 - Copyright ©2008 LG Electronics. Inc. All right reserved. LGE Internal Use Only Only for training and service purposes...
  • Page 86 September, 2008 P/NO : MFL58346401...

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