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LG MLP-F8081CL Service Manual
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LG MLP-F8081CL Service Manual

Floor standing type air conditioner
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LG

Floor Standing Type

Air Conditioner

SERVICE MANUAL
MODEL: MLP-F8081CL/AL/HL/BL/ZL
LP-C808FA0/LP-H808FA0/LP-Z808FA0
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 MLP-F8081CL

  • Page 1: Floor Standing Type

    Floor Standing Type Air Conditioner SERVICE MANUAL MODEL: MLP-F8081CL/AL/HL/BL/ZL LP-C808FA0/LP-H808FA0/LP-Z808FA0 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 ..........................9 Dimensions..............................10 Wiring Diagram............................11 Operation Details ............................16 Installation ...............................22 Operating ..............................36 3-Way Valve..............................37 Troubleshooting Guide ...........................45 Electronic Control Device ........................58 Schematic Diagram..........................61 Exploded View and Replacement Parts List..................62 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. 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 (customer). Authorized 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˚ 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, Soft Dry, Auto, Fan Cooling Model • Cooling, Heating, Soft Dry, Fan Heat Pump Model Sensing the room temperature • Room temperature sensor (Thermistor) Controlling the room temperature •...
  • Page 8 Functions Outdoor Unit Deice Control • De-ice PCB Outdoor Fan Speed Control • One speed Sensing Heat Exchanger Temperature • Heat exchanger temperature sensor (Thermistor) 8 Floor Standing Type Air Conditioner...

  • Page 9: Product Specifications

    Product Specifications Product Specifications LP-F8081HL/BL MODEL LP-F8081CL/AL LP-C808FA0 LP-H808FA0 LP-Z808FA0 LP-F8081ZL POWER SOURCE (ø, V, Hz) 3,380 – 415,50 3,380 – 415,50 3,380-415,50 3,380-415,50 3,380-415,50 COOLING CAPACITY Btu/h 71,400 71,400 75,000 75,000 75,000 20,927 20,927 21,995 21,995 21,995 INPUT 6,900 7,000 8,300 8,000...

  • Page 10: Dimensions

    Dimensions Dimensions Indoor Unit 1051 Air Outlet Vent Window Display Air Inlet Vent Earth Screw 58.5 109.5 Outdoor Unit Air Outlet Vent Air Inlet Vent 95 80 1245 10 Floor Standing Type Air Conditioner...

  • Page 11: Wiring Diagram

    Wiring Diagram Wiring Diagram Indoor & Outdoor Unit Circuit Diagram Model: LP-F8081CL/AL INDOOR UNIT CIRCUIT DIAGRAM MAIN PCB ASM GN/YL GN/YL INDOOR FAN MOTOR CONNECT TO ROOM OUTDOOR UNIT FUSE (10A) NOTE BLUE SUB PCB ASM BLACK BROWN ORANGE CONNECT TO CONTACT "R" "N" OF WHITE OUTDOOR TERMINAL BLOCK "Tmo1"...

  • Page 12: Outdoor Unit Wiring Diagram

    Wiring Diagram Model: LP-F8081HL/ZL/BL INDOOR UNIT CIRCUIT DIAGRAM MAIN PCB ASM POWER SUPPLY 3Ø 380~415V 50Hz INDOOR FAN MOTOR ROOM FUSE (10A) CONNECT TO OUTDOOR SUB PCB ASM (HOUSING ASM) Option part CONNECT TO CONTACT "T" "N" OF OUTDOOR TERMINAL BLOCK "A" DEF TH THERMISTER FOR DISCHARGE AIR RELAY FOR COMP...
  • Page 13 Wiring Diagram Model: LP-C808FA0 Service Manual 13...
  • Page 14 Wiring Diagram Model: LP-H808FA0 14 Floor Standing Type Air Conditioner...
  • Page 15 Wiring Diagram Model: LP-Z808FA0 Service Manual 15...

  • 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 1~3 seconds to prevent relay noise. (Protection of fan relay and micro chip) •...
  • Page 17 Operation Details 3. Auto Operation (Cooling Model only) The operation procedure is as following. Press Start/Stop Button Select Auto Operation Mode Check the Room temperature Auto Operation for Cooling Operation Condition Intake-air Temperature Setting temperature Fan speed Over 26°C 25°C Over 24°C~below 25.5°C Intake air -1.0°C When Switch to...

  • Page 18: Heating Mode Operation

    Operation Details 4. 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 5. 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: Soft Dry Operation Mode

    Operation Details 7. Soft Dry Operation Mode • During Soft Dry Operation, the compressor ON temperature is the setting temperature plus 2°C, the compres- sor 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 Cooling mode.
  • Page 21 Operation Details 11. Alarm mode display / only displayed while operating. CH 0 : The sensor for sensing room temperature is open or short. CH 1 : The sensor for sensing piping temperature of evaporator is open or short. 12. Function for test operation. This function shall be operated while the set not operating and start while set temperature set button( ) down and start/stop buttons pressing continuously for 3 seconds.

  • Page 22: Installation

    Installation Installation Installation of Indoor, Outdoor Unit 1) Selection of the best location Indoor unit • There should not be any heat source or steam 100cm near the unit. • There should not be any obstacles to prevent the air circulation. •...
  • Page 23 Installation 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. Drill the piping hole with 70mm diameter hole- If there is any vibration transmitted to the build- core drill at either the right or the left of indoor ing, mount the rubber underneath the outdoor...
  • Page 24 Installation 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 25 Installation 2) Preparation of installation parts and tools Installation Parts, Tools Pipe cutter (MAX 35mm Copper pipe) Cutting the pipings Remear Remove burrs from cut edges of pipes. Wrench (H5, H4 hexagonal wrench) To open the service valve Pipe bender Bending the pipings Leak detector Check a gas-leakage of connecting part...
  • Page 26 Installation Piping of Indoor unit 1) Preparation of piping Cut the pipes and the cable • Use the accessory piping kit or the pipes purchased locally. Pipe cutter • Measure the distance between the indoor and the outdoor unit. • Cut the pipes a little longer than measured Slanted Rough distance.

  • Page 27: Connecting The Cable

    Installation 3) Precautions in bending If it is necessary to bend or stretch the tubing, Spring use the spring which is attached to the tubing in stead of pipe bender. • Please make a careful notice to make a smooth R70mm line.
  • Page 28 Installation Power Supply and Wiring The unit is completely wired internally at the factory MODEL Circuit breaker capacity according to general rule of electrical technology, but local rules, if they are required, should be complied with. (BTU/h) 1) Power Supply The screws which fasten the wiring in the cas- Power source must fulfill the following conditions: ing of electrical fittings are liable to come loose...

  • Page 29: Outdoor Unit

    Installation Air Purging of the Piping and Indoor Unit The air which contains moisture and which remains in the Refrigeration cycle may cause a malfunction on the Outdoor unit compressor. Remove the caps from the 4-way(liquid side) and Service port cap 4-way(gas side) valves.
  • Page 30 Installation Set the both 3-way(liquid side) and 3-way(gas side) valves to open position with the Hexagonal wrench for the unit operation. Checking a gas leakage for the left piping • Connect the manifold gauge to the service port of 3-way(gas side) valve. Measure the pressure.
  • Page 31 Installation Checking the Drainage and Form the Piping 1) Checking the Drainage Remove the inlet grille. Check the drainage. • Pour a glass of water into the drain pan. • Ensure if water flows drain hose of indoor unit. Service Manual 31...
  • Page 32 Installation 2) Form the Piping Wrap the connecting portion of indoor unit with the Main cable insulation material and secure it with two Plastic Bands. (for the right piping) Gas side piping • If you connect an additional drain hose, the end of Connecting Cable the drain-outlet should be kept distance from the (For heater)
  • Page 33 Installation Final Check and Test Run After installing the unit, perform the final check and run- Running test should be accomplished as follows: ning test as follows: Final check points Set operation switch at "FAN" and the fan will start. Check to ensure that the fan sounds nor- Is the unit securely mounted? mal.
  • Page 34 Installation Installation Check List 1. Is the unit securely mounted and levelled? Space for Evaporator Air Flow Space for Condenser Air Flow Space for Maintenance Work Noise and Vibration Appearance 2. Is electrical wiring system adequate? Wire Size Tightened Connection Switch Size Operation Control Devices Fuse Size...
  • Page 35 Installation Running Test and Maintenance Record JOB NUMBER: POWER SUPPLY : Main Power_______ V, ________ Hz Indoor Unit Outdoor Unit Model Production No. Accessory Attached : CUSTOMER'S NAME AND ADDRESS : (PHONE NO.: INSTALLED BY: DATE: START UP BY: DATE: 1.

  • Page 36: Operating

    Operating Operating Display 14 11 15 ROOM TEMP. SET TEMP. ROOM TEMP. SET TEMP. START/STOP BUTTON HEATING OPERATION LAMP Operation starts when this button is pressed and stops when the button is pressed again. DEFROST OPERATION LAMP OPERATION MODE SELECTION BUTTON AUTO OPERATION LAMP Used to select the operation Mode.

  • Page 37: 3-Way Valve

    3-Way Valve 3-Way Valve 3-Way Valve (Liquid Side) 3-Way Valve (Gas Side) Valve cap Valve cap Open position Open position Flare nut Flare nut Closed position Closed position piping piping Service Service Service Service connection connection port cap port cap port port To outdoor unit...
  • Page 38 3-Way Valve Air purging Required tools: hexagonal wrench, adjustable wrench, torque wrench, and gas leak detector. The additional gas for air purging has been charged in the outdoor unit. However, if the flare connections have not been done correctly and there gas leaks, a gas cylinder and the charge set will be needed.
  • Page 39 3-Way Valve Pumping down Liquid side Indoor unit Outdoor unit Closed 3-Way valve Gas side Open 3-Way valve CLOSE CLOSE Purge the air • Procedure Set the 3-way(liquid side) valve to the closed Confirm that both 3-way(liquid side) and 3-way(gas position.
  • Page 40 3-Way Valve 1) Re-air purging (Re-installation) Liquid side Indoor unit Closed 3-Way Outdoor unit valve Gas side Closed 3-Way valve Gas cylinder OPEN CLOSE • Procedure Confirm that both the 3-way (liquid side) valve and Discharge the refrigerant. the 3-way(gas side) valve are set to the closed •...
  • Page 41 3-Way Valve 2) Balance refrigerant of the 3-way(liquid side), 3-way(gas side) valves (Gas leakage) Liquid side Indoor unit Outdoor unit 3-Way valve Open Gas side 3-Way valve Open OPEN CLOSE • Procedure Confirm that both the liquid side and gas side valves are set to the back seat. Connect the charge set to the 3-way(gas side) valve's port.
  • Page 42 3-Way Valve 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 Connect the vacuum pump to the center hose of charge set. Evacuation for approximately one hour. - Confirm that the gauge needle has moved toward -76cmHg (vacuum of 4 mmHg or less).
  • Page 43 3-Way Valve Gas Charging 1) Cooling mode (After Evacuation) Liquid side Indoor unit Outdoor unit Open 3-Way valve Gas side Open 3-Way valve Check valve Charging cylinder OPEN CLOSE • Procedure Connect the charge hose to the charging cylinder. This is different from previous procedures. •...
  • Page 44 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 Connect the charge hose to the charge cylinder. This is different from previous procedures. •...

  • Page 45: Troubleshooting Guide

    Troubleshooting Guide Troubleshooting Guide In general, possible trouble is classified as two causes. The one is so called Starting Failure which is caused from an electrical defect, and the other is Ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application. Unit runs but ineffective cooling Ineffective Cooling or Heating Check of cold (warm) air cir-...
  • Page 46 Troubleshooting Guide Failures to Start Check power source. Check of circuit breaker and fuse. Check control switch Check control switch. setting. Compressor only fails to Fan only fails to start start Electric heater is not energized Improper wiring Drop of power voltage Loose terminal connection.
  • Page 47 Troubleshooting Guide PACKAGE AIR CONDITIONER VOLTAGE LIMITS NAME PLATE RATING MINIMUM MAXIMUM 380 - 415 V 342 V 456 V No cooling and heating operation performed 1) Both the blower and the compressor do not work WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY Other parts than the unit Electric supply interrupted...
  • Page 48 Troubleshooting Guide 3) Only outdoor fan does not work WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY Motor Over-heated Check how it is insulated. Repair or replace it. Layer short Electric Wiring Open wire on operation Check it with a tester. Rewiring or repair.
  • Page 49 Troubleshooting Guide The Units discontinue after the operation started WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY Other parts than the unit Improper opening of the Checking Open it properly service valves in the refrigerant line Wash it by means of Checking Outdoor coil Coil is dirty *1...
  • Page 50 Troubleshooting Guide The unit is working, but not cooling and heating sufficiently (Both blower and compressor are working) WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY Load Much heat load Heat load increased. Do necessary disposal Window or door has respectively. many cracks or gaps.
  • Page 51 Troubleshooting Guide WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY Electric troubles Defective contact. Checking Repair and clean or (Magnetic Defective contact point. replace it. contactor) Rusting and faults in the iron core contact face. Defective contact of the operating switch. Others Correct it.
  • Page 52 Troubleshooting Guide Fault Cause Check/Correcitve Action Discharge pressure is lower than standard. See "Low Discharge Pressure". Check the power supply line and the Single or three phases running. contactor. High or low voltage or phase unbalance. Check the voltage and phase unbalance. Internal Refrigerant short charge or leakage.
  • Page 53 Troubleshooting Guide Electronic Parts Troubleshooting Guide 1) No cooling operation performed. Is the AC220V (AC 240 V) between Connector(CN- outunit) of Main P.C.B Is the input power AC220V (AC240V) at COMP Magnetic coil? Is the unit operating? Check the magnetic Check the wiring contactor of outdoor unit.
  • Page 54 Troubleshooting Guide 2) Indoor fan does not operate. Is the unit operating? ON/OFF S/W ON Is the DC5V at 20 pin of MICOM? Is the DC5V at 21 pin of MICOM? Is the DC5V at 22 pin of MICOM? Replacement MICOM and check the EVA-Th Is the DC12V at each...
  • Page 55 Troubleshooting Guide 3) The unit does not operate. Is the AC220V 1. Check the electric connections (240V) at Trans input terminal? 2. Check the fuse of Main PCB ASM Is the AC12-18V at Replacement Trans Trans (2nd)? Is the connector of Check the connector of Main/Display correct? Main/Display...
  • Page 56 Troubleshooting Guide 5) No heating operation performed. Is the AC220V (AC 240 V) between connector (CN-outunit) 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 57 Troubleshooting Guide 6) No heater operation performed. Is the heating operating? Select the heating operation mode. Is the Heat S/W of Main Heat S/W "ON" PCB "ON"? Heater S/W "ON" Is the heater S/W of Main PCB"ON"? Replacement MICOM Is the DC 5V at 58 pin of MICOM Is the DC 12V at eack terminal? Replacement IC02M...

  • Page 58: Electronic Control Device

    Electronic Control Device Electronic Control Device Main P.C.B ASSY 58 Floor Standing Type Air Conditioner...
  • Page 59 Electronic Control Device DISPLAY P.C.B ASSY SUB P.C.B ASSY RY1 (HIGH) PWB: 6870AQ2241 ASM: 6871AQ2242 CN-MOTOR CN-RELAY RY2 (MIDDLE) CN-INPUT RY3 (LOW) FUSE 250V/T10A Service Manual 59...
  • Page 60 Electronic Control Device DE-ICER P.C.B ASSY 60 Floor Standing Type Air Conditioner...

  • Page 61: Schematic Diagram

    Schematic Diagram Schematic Diagram Circuit and Troubleshooting Service Manual 61...

  • Page 62: Exploded View And Replacement Parts List

    Exploded View and Replacement Parts List Exploded View and Replacement Parts List Indoor Unit 1) Exploded View 135310 268711-1 359012 336610-2 152302 W0CZZ 268711-2 336610-1 268711-4 135313 -62- Floor Standing Type Air Conditioner...
  • Page 63 Exploded View and Replacement Parts List 135515 346810 354212 330870 Service Manual -63-...
  • Page 64 Exploded View and Replacement Parts List 2) Replacement Parts List Location PART No. DESCRIPTION REMARK LP-F8081AL LP-F8081BL LP-F8081CL LP-F8081ZL LP-F8081HL 135310 GRILLE ASSEMBLY,DIFFUSER(INDOOR) 3531A20105B 3531A20105B 3531A20105B 3531A20105B 3531A20105B 135313 GRILLE ASSEMBLY,INLET 3530AP1109A 3530AP1109A 3530AP1109A 3530AP1109A 3530AP1109A 135515 COVER ASSY,TOP(INDOOR) 3551AP2388A 3551AP2388A 3551AP2388A 3551AP2388B 3551AP2388A 152302 FILTER ASSY,A/C 5231AP3330A 5231AP3330A 5231AP3330A 5231AP3330A 5231AP3330A...
  • Page 65 Exploded View and Replacement Parts List Location PART No. DESCRIPTION REMARK LP-C808FA0 LP-H808FA0 LP-Z808FA0 135310 GRILLE ASSEMBLY,DIFFUSER(INDOOR) 3531A20105B 3531A20105B 3531A20105B 135313 GRILLE ASSEMBLY,INLET 3530AP1109A 3530AP1109A 3530AP1109A 135515 COVER ASSY,TOP(INDOOR) 3551AP2388A 3551AP2388A 3551AP2388A 152302 FILTER ASSY,A/C 5231AP3330A 5231AP3330A 5231AP3330A 268711-1 PWB(PCB) ASSY,DISPLAY 6871AQ3143Q 6871AQ3143R 6871AQ3143R...
  • Page 66 Exploded View and Replacement Parts List Outdoor Unit 1) Exploded View -66- Floor Standing Type Air Conditioner...
  • Page 67 Exploded View and Replacement Parts List 2) Replacement Parts List Location PART No. DESCRIPTION REMARK LP-F8081AL LP-F8081BL LP-F8081CL LP-F8081ZL LP-F8081HL 268711 PWB(PCB) ASSY,DEICER 6871A20015T 6871A20015T 6871A20015T 349490 ORIFICE 4948AP1242R 4948AP1242R 4948AP1242R 4948AP1242R 4948AP1242R 549610 MOUNT ASSY,MOTOR(OUTDOOR) 3A00434G 3A00434G 3A00434G 3A00434G 3A00434G 430411 BASE ASSY,WELD[OUTDOOR]...
  • Page 68 Exploded View and Replacement Parts List Location PART No. DESCRIPTION REMARK LP-C808FA0 LP-H808FA0 LP-Z808FA0 268711 PWB(PCB) ASSY,DEICER 6871A20015T 6871A20015T 349490 ORIFICE 4948AP1242R 4948AP1242R 4948AP1242R 549610 MOUNT ASSY,MOTOR(OUTDOOR) 3A00434G 3A00434G 3A00434G 430411 BASE ASSY,WELD[OUTDOOR] 3041A10037B 3041A10037D 3041A10037D 435311 GRILLE ASSY,DISCHARGE(OUTDOOR) 2A00144P 2A00144P 2A00144P 437210 PANEL ASSY,FRONT SUB...
  • Page 69 April, 2005 P/No.: 3828A30074P Printed in Korea...

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