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Room Air Conditioner

SERVICE MANUAL
CAUTION
-BEFORE SERVICING THE UNIT, READ THE SAFETY
PRECAUTIONS IN THIS MANUAL.
-ONLY FOR AUTHORIZED SERVICE PERSONNEL.

MODEL: W121CA
W122CA
W122CM
W091CA
W092CA
 CONTENTS
1. PREFACE
1.1 SAFETY PRECAUTIONS................................................................................................................................2
1.2 INSULATION RESISTANCE TEST.................................................................................................................2
1.3 SPECIFICATIONS...........................................................................................................................................2
1.4 FEATURES .....................................................................................................................................................3
1.5 CONTROL LOCATIONS .................................................................................................................................3
2. DISASSEMBLY INSTRUCTIONS
2.1 MECHANICAL PARTS ....................................................................................................................................5
2.1.1 FRONT GRILLE .....................................................................................................................................5
2.1.2 CABINET................................................................................................................................................5
2.1.3 CONTROL BOX .....................................................................................................................................5
2.2 AIR HANDLING PARTS ..................................................................................................................................6
2.2.1 COVER (AT THE TOP) ..........................................................................................................................6
2.2.2 BLOWER................................................................................................................................................6
2.2.3 FAN ........................................................................................................................................................6
2.2.4 SHROUD................................................................................................................................................7
2.3 ELECTRICAL PARTS .....................................................................................................................................7
2.3.1 MOTOR ..................................................................................................................................................7
2.3.2 COMPRESSOR .....................................................................................................................................7
2.3.3 CAPACITOR ..........................................................................................................................................7
2.3.4 POWER CORD ......................................................................................................................................8
2.3.5 THERMISTOR........................................................................................................................................8
2.3.6 SYNCHRONOUS MOTOR.....................................................................................................................8
2.4 REFRIGERATION CYCLE ..............................................................................................................................9
2.4.1 CONDENSER ........................................................................................................................................9
2.4.2 EVAPORATOR ......................................................................................................................................9
2.4.3 CAPILLARY TUBE .................................................................................................................................9

3. TROUBLESHOOTING GUIDE
3.1 OUTSIDE DIMENSIONS...............................................................................................................................12
3.2 PIPING SYSTEM...........................................................................................................................................12
3.3 TROUBLESHOOTING GUIDE ......................................................................................................................13
4. SCHEMATIC DIAGRAM
4.1 CIRCUIT DIAGRAM ......................................................................................................................................22
4.2 ELECTRONIC CONTROL DEVICE ..............................................................................................................23
4.3 COMPONENTS LOCATION(FOR MAIN P.C.B ASM) .......................................................................................................24
4.4 COMPONENTS LOCATION(FOR DISPLAY P.C.B ASM) .......................................................................................................25
5. EXPLODED VIEW ..................................................................................................................................26
6. REPLACEMENT PARTS LIST ........................................................................................................27

-1-
1. PREFACE
This service manual provides various service information, including the mechanical and electrical parts, etc.
This room air conditioner was manufactured and assembled under a strict quality control system.
The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.

1.1 SAFETY PRECAUTIONS 1.2 INSULATION RESISTANCE TEST

1. When servicing, set the POWER of CONTROL BOARD to 1. Unplug the power cord and connect a jumper between 2
Off and unplug the power cord. pins (black and white).
2. Observe the original lead dress. 2. The grounding conductor (green or green and yellow) is to
If a short circuit is found, replace all parts which have been be open.
overheated or damaged by the short circuit. 3. Measure the resistance value with an ohm meter between
3. After servicing, make an insulation resistance test to the jumpered lead and each exposed metallic part on the
prevent the customer's exposure to shock hazards. equipment at all Mode [except POWER OFF].
4. The value should be over 1 M.
1.3(A) SPECIFICATIONS
ITEMS W121CA W122CA W122CM W091CA W092CA
POWER SUPPLY 1,115V,60Hz 1,220V,60Hz 1,115V,60Hz 1,220V,60Hz
COOLING CAPACITY(Btu/hr) 12000 9000
INPUT (W) 1220 1000
RUNNING CURRENT (A) 11 5.5 9.3 4.7
REFRIGERANT(R-22) 360g 390g 330g (11.6 oz)
INDOOR 26.7(DB),19.4(WB)
OPERATING TEMPERATURE OUTDOOR 35(DB),23.9(WB)
EVAPORATOR 2 ROW 16STACKS 2 ROW 14STACKS
CONDENSER 2 ROW 18STACKS 2 ROW 16STACKS
FAN,INDOOR TURBO BLOWER
FAN,OUTDOOR PRPPELLER TYPE FAN WITH SLINGER RING
FAN SPEEDS,FAN/COOLING 3/3
FAN MOTOR 6 POLES
OPERATION CONTROL ROTARY SWITCH WIRELESS REMOCON ROTARY SWITCH
ROOM TEMP.CONTROL THERMOSTAT THERMISTER THERMOSTAT
AIR DIRECTION CONTROL VERTICAL LOUVER(RIGHT&LEFT)
CONSTRUCTION HORIZONTAL LOUVER(UP/DOWN)
COMPRESSOR SLIDE IN-OUT CHASSIS
PROTECTOR FAN MOTOR INTERNAL OVERLOAD PROTECTOR
3 WIRE WITH GROUNDING
POWER CORD CORD CONNECTED TYPE(ATTACHMENT PLUG:OPTION)
DRAIN SYSTEM DRAIN PIPE OR SPLASHED BY FAN SLINGER
NET WEIGHT (Ibs/kg) 97/44 66/30
(INCH) 23.62 x 14.96 x 21.85 21.73 x 22.12 x 17.16
OUTSIDE DIMENSION (MM) 600 x 380 x 555 552 x 562 x 436
* DB:Dry Bulb ** WB:Wet Bulb
NOTE : Specifications are subject to minor change without notice for further improvement.
2
1.4 FEATURES
Designed for cooling only. Side air-intake, side cooled-air discharge.
Powerful and quiet cooling. Built in adjustable THERMISTOR.
Slide-in and slide-out chassis for the simple installation Washable one-touch filter.
and service. Compact size.
Reversible inlet grille. Part B

1.5 CONTROL LOCATIONS

VENTILATION
The ventilation lever must be in the CLOSE position in
order to maintain the best cooling conditions.
When a fresh air is necessary in the room, set the
ventilation lever to the OPEN position.
The damper is opened and room air is exhausted.
Part A
NOTE: Before using the ventilation feature, make
the lever, as shown. First, pull down part
to horizontal line with part .

Precaution: The Remote Control unit will not function

properly if strong light strikes the sensor
window of the air conditioner or if there CLOSE VENT OPEN
are obstacles between the Remote
Control unit and the air conditioner.

THERMOSTAT
Thermostat will automatically control the Thermostat Operation
temperature of the room. Select the higher number 5 Off
4 6
Med High
for the lower temperature of the room. The Fan Cool
temperature is selected by positioning the knob to 3 7

the desired position.

2 8
The 5 or 6 position is a normal setting for average Low Med
conditions. 1 9 Fan Cool
Low Cool

OPERATION
OFF : Turns the air conditioner off.
MED FAN : Permits the medium fan speed operation
without cooling.
LOW FAN : Permits the low fan speed operation
without cooling.
HIGH COOL: Permits cooling with the high fan speed
operation.
MED COOL : Permits cooling with the medium fan
speed operation.
LOW COOL: Permits cooling with the low fan speed
operation.

3
 DISPLAY
MODE
Everytime you push this button, it will toggle REMOCON SIGNAL RECEIVER
between Cool, Fan and Dry. AUTO RESTART SWITCH
In failure of electric power, if the switch is set to "ON",
the unit runs unit runs as previous setting operation
when power returns.
POWER
To turn the air conditioner ON, push the button.
To turn the air conditioner OFF, push the button again.
This button takes priority over any other buttons.
When you first turn it on, the air conditioner is on the
High cool mode and the temp. at 72F(22C)

TEMPERATURE SETTING
This button can automatically control the temperature
ON/OFF TIMER of the room. The temperature can be set within a range
Everytime you push this button, timer is set as follows. of 60F to 86F by 1F.(16C to 30C by 1C)
(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours 7Hours Select the lower number for lower temperature of the room.
8Hours 9Hours 10Hours 11Hours 12Hours Cancel)
The Setting Temperature will be raised by 2F(1C) 30min. FAN SPEED
later and by 2F after another 30 min. Everytime you push this button it is set as follows.
{High(F3) Low(F1) Med(F2) High(F3)...}.
Remote controller
Precaution: The Remote Controller will not function properly if strong light strikes the sensor window of the air conditioner or
if there are obstacles between the Remote Controller and the air conditioner.

1 ON/OFF TIMER
- STOPPING OPERATION
Everytime you push this button, when the air conditioner is operating, timer is set as follows. (1Hour
2Hours 3Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours 10Hours
11Hours 12Hours Cancel)
2
The Setting Temperature will be raised by 2F(1C) 30min. later and by 2F(1C) after another 30 min.
- STARTING OPERATION
Everytime you push this button, when the air conditioner is not operating, timer is set as follow. 3 1
(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours
10Hours 11Hours 12Hours Cancel) 4 6
2 AUTO SWING (Optional) 5
The vertical louver swings horizontally by the automatic system and stops when you press
the button again.
3 MODE
Everytime you push this button, it will toggle between Cool, Fan and Dry.
6
4 FAN SPEED
Everytime you push this button it is set as follows. {High(F3) Low(F1) Med(F2) High(F3)...}.
5
5 TEMPERATURE SETTING
This button can automatically control the temperature of the room.
The temperature can be set within a range of 60F to 86F by 1F.(16C to 30C by 1C) 4
Select the lower number for lower temperature of the room.
1 3
6 POWER
To turn the air conditioner ON, push the button. To turn the air conditioner OFF, push the button again. 2
This button takes priority over any other buttons.
When you first turn it on, the air conditioner is on the High cool mode and the temp. at 72F(22C).

4
2. DISASSEMBLY INSTRUCTIONS
-Before the following disassembly, POWER SWITCH is set to OFF and disconnected the power cord.

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE
1. Open the inlet grille upward or downward.
2. Remove the screw which fastens the front grille.
3. Pull the front grille from the right side.
4. Remove the front grille. (See Fig. 1)
5. Re-install the component by referring to the
removal procedure.
NOTE: Markrof inlet grille means opening direction.

Figure 1

2.1.2 CABINET
1. After disassembling the FRONT GRILLE, remove
the screws which fasten the cabinet at both sides.
Keep these for later use.
2. Remove the two screws which fasten the cabinet
at back. (See Fig. 2)
3. Pull the base pan forward.

2.1.3 CONTROL BOX

1. Remove the front grille. (Refer to section 2.1.1) Figure 2
2. Pull the base pan forward so that you can remove
the 2 screws which fasten the cover control at the
right side. (See Fig. 3)
3. Remove the 3 screws which fasten the control
box. (See Fig. 3)
4. Discharge the capacitor by placing a 20,000 ohm
resistor across the capacitor terminals.
5. Disconnect two wire housings in the control box.
6. Pull the control box forward completely.
7. Re-install the components by referring to the
removal procedure. (See Fig. 3)
(Refer to the circuit diagram found on page 23 in
this manual and on the control box.)
Figure 3

5
2.2 AIR HANDLING PARTS
2.2.1 COVER (AT THE TOP)
1. Remove the front grille. (Refer to section 2.1.1)
2. Remove the cabinet. (Refer to section 2.1.2)
3. Remove 11 screws which fasten the brace and
covers.
4. Remove the covers and the brace. (See Fig. 4)
5. Re-install the components by referring to the
removal procedure, above.

Figure 4 (a) Figure 4 (b)

2.2.2 BLOWER
1. Remove the cover. (Refer to section 2.2.1)
2. Remove the 3 screws which fasten the
evaporator at the left side and the top side.
(See Fig. 4)
3. Move the evaporator sideward carefully.
4. Remove the orifice from the air guide carefully.
5. Remove the clamp spring which is clamped to the
boss of blower by hand plier. (See Fig. 5)
Figure 5
6. Pull the blower outward, without touching blades.
(See Fig. 6)
7. Re-install the components by referring to the
removal procedure, above.

2.2.3 FAN Figure 6

1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the brace and shroud cover.
(Refer to section 2.2.1)
3. Remove the 5 screws which fasten the condenser.
4. Move the condenser sideways carefully.
5. Remove the clamp which secures the fan.
6. Remove the fan. (See Fig. 7)
7. Re-install the components by referring to the
removal procedure, above.

Figure 7 (a) Figure 7 (b)

6
2.2.4 SHROUD
1. Remove the fan. (Refer to section 2.2.3)
2. Remove the 2 screws which fasten the shroud.
3. Remove the shroud. (See Fig. 8)
4. Re-install the component by referring to the
removal procedure, above.

2.3 ELECTRICAL PARTS

2.3.1 MOTOR
1. Remove the cabinet. (Refer to section 2.1.2) Figure 8 (a) Figure 8 (b)
2. Remove the cover control and disconnect a wire
housing in control box. (Refer to section 2.1.3)
3. Remove the blower. (Refer to section 2.2.2)
4. Remove the fan. (Refer to section 2.2.3)
5. Remove the 4 screws which fasten the motor.
(See Fig. 9)
6. Remove the motor.
7. Re-install the components by referring to the
removal procedure, above.

2.3.2 COMPRESSOR Figure 9

1. Remove the cabinet. (Refer to section 2.1.2)
2. Discharge the refrigerant by using a Refrigerant
Recovery System.
3. Disconnect the 3 leads from the compressor.
4. After purging the unit completely, unbraze the
suction and discharge tubes at the compressor
connections.
5. Remove the 3 nuts and the 3 washers which
fasten the compressor. (See Fig. 10)
6. Remove the compressor.
7. Re-instill the components by referring to the
removal procedure, above.

Figure 10

2.3.3 CAPACITOR
1. Remove the control box. (Refer to section 2.1.3)
2. Remove the screw which fasten the display panel.
3. Disconnect the 2 leads from the rocker switch and
remove the panel.
4. Remove a screw and unfold the control box.
(See Fig. 11)
5. Remove the screw and the clamp which fastens
the capacitor. (See Fig. 11)
6. Disconnect all the leads of capacitor terminals.
7. Re-install the components by referring to the
removal procedure, above.

Figure 11

7
2.3.4 POWER CORD
1. Remove the control box. (Refer to section 2.1.3)
2. Unfold the control box. (Refer to section 2.3.3)
3. Disconnect the grounding screw from the control
box.
4. Disconnect 2 receptacles.
5. Remove a screw which fastens the clip cord.
6. Pull the power cord. (See Fig. 12)
7. Re-install the component by referring to the
removal procedure, above.
(Use only one ground-marked hole for ground
connection.)
8. If the supply cord of this appliance is damaged, it
must be replaced by the special cord.
(The special cord means the cord which has the
same specification marked on the supply cord
fitted to the unit.)
Figure 12

2.3.5 THERMISTOR
1. Remove the control box. (Refer to section 2.1.3)
2. Unfold the control box. (Refer to section 2.3.3)
3. Disconnect the thermistor terminals from main
P.W.B assembly.
4. Remove the thermistor.
5. Re-install the components by referring to the
removal procedure above. (See Figure 13)

Figure 13

8
2.4 REFRIGERATION CYCLE

CAUTION

Discharge the refrigerant system using FreonTM

Recovery System.
If there is no valve to attach the recovery system,
install one (such as a WATCO A-1) before
venting the FreonTM. Leave the valve in place
after servicing the system.

2.4.1 CONDENSER
1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the brace and the shroud cover.
(Refer to section 2.2.1) Figure 15 (a)
3. Remove the 5 screws which fasten the condenser.
4. After discharging the refrigerant completely,
unbraze the interconnecting tube at the condenser
connections.
5. Remove the condenser.
6. Re-install the components by referring to notes.
(See Fig. 15)

2.4.2 EVAPORATOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the top cover and the brace.
(Refer to section 2.2.1)
3. Discharge the refrigerant completely.
4. Remove the 3 screws which fasten the evaporator
at the left side and the top side. Figure 15 (b)
5. Move the evaporator sideward carefully and then
unbraze the interconnecting tube at the evaporator
connectors.
6. Remove the evaporator.
7. Re-install the components by referring to notes.
(See Fig. 16)

2.4.3 CAPILLARY TUBE

1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the brace. (Refer to section 2.2.1)
3. After discharging the refrigerant completely,
unbraze the interconnecting tube at the capillary
tube.
4. Remove the capillary tube. Figure 16
5. Re-install the components by referring to notes.

9
 NOTES
Replacement of the refrigeration cycle.
1. When replacing the refrigeration cycle, be sure to
discharge the refrigerant system using a FreonTM
recovery System.
If there is no valve to attach the recovery system,
install one (such as a WATCO A-1) before venting
the FreonTM. Leave the valve in place after
servicing the system.
2. After discharging the unit completely, remove the
desired component, and unbrace the pinch-off
tubes.
3. Solder service valves into the pinch-off tube ports,
leaving the valves open.
4. Solder the pinch-off tubes with Service valves.
5. Evacuate as follows.
1) Connect the vacuum pump, as illustrated Fig.
17A.
2) Start the vacuum pump, slowly open manifold
valves A and B with two full turns
counterclockwise and leave the valves closed.
The vacuum pump is now pulling through valves
A and B up to valve C by means of the manifold
and entire system.
CAUTION
If high vacuum equipment is used, just crack
valves A and B for a few minutes, then open
slowly with the two full turns counterclockwise.
This will keep oil from foaming and being
drawn into the vacuum pump.
3) Operate the vacuum pump for 20 to 30 minutes,
until 600 microns of vacuum is obtained. Close
valves A and B, and observe vacuum gauge for
a few minutes. A rise in pressure would
indicate a possible leak or moisture remaining in
the system. With valves A and B closed, stop
the vacuum pump.
4) Remove the hose from the vacuum pump and
place it on the charging cylinder. See Fig. 17B.
Open valve C.
Discharge the line at the manifold connection.
5) The system is now ready for final charging.
10
6. Recharge as follows :
1) Refrigeration cycle systems are charged from the
High-side. If the total charge cannot be put
in the High-side, the balance will be put in the
suction line through the access valve which you
installed as the system was opened.
2) Connect the charging cylinder as shown in Fig. 17B.
With valve C open, discharge the hose at the
manifold connection.
3) Open valve A and allow the proper charge to
enter the system. Valve B is still closed.
4) If more charge is required, the high-side will not
take it. Close valve A.
5) With the unit running, open valve B and add the
balance of the charge.
a. Do not add the liquid refrigerant to the Low-
side.
b. Watch the Low-side gauge; allow pressure to
rise to 30 lbs.
c. Turn off valve B and allow pressure to drop.
d. Repeat steps B and C until the balance of the
charge is in the system.
6) When satisfied the unit is operating correctly,
use the pinch-off tool with the unit still running
and clamp on to the pinch-off tube. Using a tube
cutter, cut the pinch-off tube about 2 inches from
the pinch-off tool. Use sil-fos solder and solder
pinch-off tube closed. Turn off the unit, allow it to
set for a while, and then test the leakage of the
pinch-off connection.
Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pinch-off tool
capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service
valve.

COMPOUND GAUGE
CONDENSER
(HIGH PRESSURE SIDE)
MANIFOLD
GAUGE
B A

CAPILLARY TUBE

SEE INSETS
BELOW

EVAPORATOR
(LOW PRESSURE SIDE)

COMPRESSOR

LOW HI

A
B B A
EXTERNAL
VACUUM PUMP
CHARGING
CYLINDER
C

Figure 17A-Pulling Vacuum Figure 17B-Charging

11
3. TROUBLESHOOTING GUIDE
3.1 OUTSIDE DIMENSIONS
555(WC), 486(WG) 598(WC), 467(WG)

380(WC), 350(WG)
3.2 PIPING SYSTEM
CONDENSER COIL

FAN
CAPILLARY TUBE
MOTOR

COMPRESSOR

BLOWER

EVAPORATOR COIL

: REFRIGERANT FLOW
Following is a brief description of the important components and their functions in the refrigeration system.
Refer to Fig. 18 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle.

ROOM AIR CONDITIONER

CYCLE OF REFRIGERATION
EVAPORATOR COILS CONDENSER COILS
VAPOR INLET
SUCTION LINE
COMPLETE LIQUID HOT
COOL LOW PRESSURE VAPOR
BOIL OFF POINT DISCHARGED
COOLED AIR
AIR
ROOM AIR HEAT LOAD

OUTSIDE COOLING
AIR FOR REFRIGERANT
PASS THROUGH
MOTOR

COMPRESSOR

OIL
LIQUID
PRESSURE LIQUID OUTLET
DROP
(LIQUID REFRIGERANT)
HIGH PRESSURE VAPOR

CAPILLARY TUBE LIQUID PEFRIGERANT

LOW PRESSURE VAPOR
Figure 18

12
3.3 TROUBLESHOOTING GUIDE
In general, possible trouble is classified in two causes.
The one is 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 poor cooling

Ineffective Cooling

Check of cold air circulation Check of outdoor coil Check heat load increase.
for smooth flow. (heat exchanger) & the fan
operation.

Unexpected residue
Dirty indoor coil Check gas leakage.
(Heat exchanger)

Overloaded Circuit
Malfunction of fan Repair gas leak.

Check of inside gas

Clogged of air filter Replacement of unit if the pressure.
unit is beyond repair.

Obstruction at air outlet

Adjusting of refrigerant
charge

Stop of auto air-swing

Malfunction of compressor

Correct above trouble

Replacement of
compressor
Check clogging in
refrigeration circuit.

Satisfactory operation with

temperature difference of
Repair clogging in inlet & outlet air ; 44.6~50F
refrigeration circuit.

13
 Fails to Start

Check of power source. Check of circuit breaker

and fuse.

Check of control switch

Check of control panel.
setting.

Only compressor fails to Only fan fails to start.

start.

Improper wiring.
Drop of power voltage.

Improper thermistor setting

Defect of fan motor
Defect of compressor capacitor.
capacitor.

Loose terminal connection.

Irregular motor resistance
( ).
Check capacitor. Irregular motor insulation
( ).
Improper wiring

Replacement.
Replacement of fan motor

Irregular motor resistance ( ) Regular but fails to start

Irregular motor insulation ( )

Replacement of compressor
(locking of rotor, metal)
Replacement of compressor
(Motor damaged)

14
ELECTRIC PARTS TROUBLESHOOTING GUIDE:
MODEL: W122CM

Possible Trouble 1 The unit does not operate.

NO Check the Fuse.

Is the Trans output power the
same as specified? Check the wiring diagram.

YES

NO NO Check the Main

Is the Trans output power Is shorted the Trans. output?
about AC 14V? P.W.B pattern.

YES YES
Exchange the Trans.

Is output Voltage of IC01D NO Exchange D02D~D05D.

DC 12V? Exchange IC01D.

YES

NO
Is output Voltage of IC02D Exchange IC02D.
DC 5V?

YES

Is the reset circuit all right? NO

Exchange IC01A.
(The No.14 of Micom
is 5V.)
YES

Is the
connection between NO Connect connector
Main and Display exactly.
all right?
YES

NO Check the P.W.B

Is the voltage No.18 of Micom pattern.
DC 5V?

YES

Exchange Main P.W.B Ass'y.

15
 Possible Trouble 2 The compressor does not operate.

Is Temp.
NO
setting set lower than Room Set the Temp. setting to higher Temp.
Temp.-0.5C?

YES

Is the voltage No.10 NO Is the voltage N0.7 of NO NO

Is the Unit for 3 minutes
of IC01M 0V? IC01M DC 5V? delay?

YES YES YES

Check the RY-COMP. Exchange IC01M. Wait 3 Minutes

Check the wiring
Diagram.
Exchange MAIN
P.W.B Ass'y.

Possible Trouble 3 The compressor always operate.

NO Connect LEAD Wire to

Is the wire connection of RY-COMP again.
RY-COMP all right?

YES

Check the RY-COMP.

Possible Trouble 4 Fan does not operate.

Is the voltage NO.1 or 2 or 4 NO

Exchange IC01M.
of IC01M DC 5V?

YES

Is the voltage
NO.13 or 15 or 16 NO Exchange IC01M.
of IC01M 0V?

YES

Check the RY-Hi or

RY-Lo.
Check the wiring diagram.

16
 The function of Energy Saver does not operate.
Possible Trouble 5

Is the Knob of SW1 NO Set the Knob of SW1

set to left position? to left position.

YES

Check the SW1.

Is the voltage No.1 of NO
Check the pattern of
CN-DISP of Main PCB
Ass'y DC 5V? Main & Display PCB.

YES

Reference to
OWNER'S MANUAL.

Romote controller does not operate.

Possible Trouble 6

Is the voltage of Battery NO

Exchange the battery.
about over 2.3V?

YES

Is the voltage No.16 NO

of CN-DISP1 on Main P.W.B Check the P.W.B pattern.
Ass'y DC 5V?

YES

Is the connection of NO Connect connector to

CN-DISP1 all right? CN-DISP1 exactly.

YES

Exchange Receiver Ass'y.

17
 Possible Trouble 7 It displays abnormally on Display P.W.B Ass'y.

NO
Is the IC01G all right? Exchange IC01G.

YES
NO
NO Connect connector
Is the connection of
to CN-DISP1 exactly.
CN-DISP1 all right?

YES

Does the Q01G, NO

Q02G, Q03G Q04G operate normally Exchange Q01G,
on main P.W.B Ass'y? Q02G, Q03G, Q04G

YES

Exchange the display

P.W.B Ass'y.

18
ROOM AIR CONDITIONER VOLTAGE LIMITS

NAME PLATE RATING MINIMUM MAXIMUM

208~230 10% 187V 253V

COMPLAINT CAUSE REMEDY

Fan motor will not run. No power Check voltage at outlet. Correct if none.

Power supply cord Check voltage to rotary switch. If none, check

power supply cord. Replace cord if circuit is
open.

Rotary switch Check switch continuity. Refer to wiring diagram

for terminal identification. Replace switch if
defective.

Wire disconnected or Connect wire. Refer to wiring diagram for

connection loose terminal identification. Repair or replace loose
terminal.

Capacitor (Discharge Test capacitor.

capacitor before testing.) Replace if not within 10% of manufacturer's
rating. Replace if shorted, open, or damaged.

Will not rotate Fan blade hitting shroud or blower wheel hitting
scroll. Re-align assembly.

Units using slinger ring condenser fans must

have 0.22~0.25 inch clearance to the base.
If necessary, shim up the bottom of the fan motor
with mounting screw(s).

Check fan motor bearings; if motor shaft will not

rotate, replace the motor.

Fan motor runs. Revolves on overload Check voltage. See limits on this page.

If not within limits, call an electrician.

Test capacitor.
Check bearings. Does the fan blade rotate
freely?
If not, replace fan motor.

Pay attention to any change from high speed to

low speed. If the speed does not change,
replace the motor.

19
 COMPLAINT CAUSE REMEDY

Fan motor noise. Fan If cracked, out of balance, or partially missing,

replace it.

Blower If cracked, out of balance, or partially missing,

replace it.

Loose set screw Tighten it.

Worn bearings If knocking sounds continue when running or

loose, replace the motor. If the motor hums or
noise appears to be internal while running,
replace motor.

Compressor will not run, Voltage Check voltage. See the limits on the preceding
fan motor runs. page. If not within limits, call an electrician.

Wiring Check the wire connections; if loose, repair or

replace the terminal. If the wires are discon-
nected, refer to wiring diagram for identification,
and replace the wires. Check the wire connections;
If not according to the wiring diagram, correct
the connections.

Rotary Check for continuity, refer to the wiring diagram

for terminal identification. Replace the switch if
the circuit is open.

Thermistor Check the TEMP control. If not at the lowest

number, set TEMP control to this setting and
restart the unit.
Check the continuity of the thermistor. Replace
the thermistor if the circuit is open.

Capacitor (discharge Check the capacitor.

capacitor before Replace if not within 10% of manufacturers
servicing.) rating, replace if shorted, open, or damaged.

Compressor Check the compressor for open circuit or

ground. If open or grounded, replace the
compressor.

Overload Check the compressor overload if externally mounted.

Replace if open. (If the compressor temperature is
high, remove the overload, cool, and retest.)

Compressor cycles on Voltage Check the voltage. See the limits on the
overload. preceding page. If voltage is not within these limits,
call an electrician.

Overload Check overload, if externally mounted.

Replace if open. (If the compressor temperature
is high, remove the overload, cool, and retest.)

20
 COMPLAINT CAUSE REMEDY

Compressor cycles on Fan motor If not running, determine the cause. Replace if
overload. required.

Condenser air flow Remove the cabinet, inspect the interior surface
restriction of the condenser. If restricted, clean carefully
with a vacuum cleaner (do not damage fins) or
brush. Clean the interior base before
re-assembling.

Condenser fins If the condenser fins are closed over a large

(damaged) area on the coil surface, head pressures will
increase, causing the compressor to cycle.
Straighten the fins or replace the coil.

Capacitor Test the capacitor.

Wiring Check the terminals. If loose, repair or replace.

Refrigeration system Check the system for a restriction.

Insufficient cooling Air filter If restricted, clean or replace.

Exhaust damper door Close if open.

Unit undersized Determine if the unit is properly sized for the

area to be cooled.

Excessive noise Blower or fan Check the set screw, or clamp. If loose or miss-
ing, correct. If the blower or fan is hitting scroll
or barrier, rearrange the air handling parts.

Copper tubing Remove the cabinet and carefully rearrange the

tubing not to contact the cabinet,
compressor, shroud, and barrier.

Auto air-swing fails. Wiring Check terminals. If loose, repair or replace.

Synchronous motor. Check the synchronous motor for open circuit.

21
4. SCHEMATIC DIAGRAM
4.1 CIRCUIT DIAGRAM
MODEL : W-121CA, W-122CA, W-091CA,W-092CA

POWER INPUT
WH WH

ROTARY SWITCH GN(GN/YL)

8 L RD RD
7
5 6 H BK BK

4 M BL BL
3
MOTOR
1 2 OR(BR)

YL CAPACITOR

YL
F

OR(BR) C

BL BK BK
R
RD RD
COMP S

BR(YL) BL BL
C
OLP

THERMOSTAT

WIRING DIAGRAM
3854A22014A

MODEL : W-122CM

POWER INPUT
WH WH

GN(GN/YL) THERMISTOR
BK BK CN-TH1
RD RD
BL BL
MOTOR
DISPLAY PCB ASSY

OR(BR) OR(BR)
FFC
CN-DISP
RY-MID
RY-LOW

RY-HI

YL YL

CAPACITOR

C
OR(BR)
BK
RD
MAIN P.W.B ASSY

BK
R
ZNR
RD TRANS/
COMP S RY-COMP SMPS
BR(YL) BL BL 4 3
C
OLP
FUSE 250V T2A

WIRING DIAGRAM 3854A22014B

- 22-
 R01A
20K
5V 5V
OSC01B
R02H R01H RT8.00MG 1
CN-TH1 6.2K 12.1K 3 IC01A
ROOM-TH SMW250-04 1% 1% 3.6V S7136
R01B C01A + C02A 2
1 1 1M 0.01 1uF
50V 50V
2 2

3 2 EEPROM
5V 24LC01BT
4 4 1 Q04G
1 A101S 5V
R03H R21H R22H A0 Vcc 8 5V
Q03G
PIPE-TH 12.1K 12.1K 2 7 R02P R03P A101S
5V A1 WP 20K 20K Q02G
1% 1%
3 6 A101S
A2 SCL
Q01G
4 A101S
GND SDA 5

OR01H OR02H

Osc in
Osc out
/Reset

Option2
Option1
Pipe TH
Room TH
VAref
VSS
TEST
Tx
22 21 20 19 18 17 16 15 14 13 12
RY-COMP 10 7 COMP Rx R04P
12V 23 11
RY-SYNC 1K 2
11 6 SYNC SDA 3 4 5
24 10
RY-4WAY 12 5 4WAY SCL
25 9
RY-LOW 13 4 LOW Digit4 (Scan4) 16 15 13
26 8 14
14 3 HVB Digit3 (Scan3)
27 MICOM 7
RY-MED 15 2 ION TMP87CH47U Digit2 (Scan2)
28 6
RY-HI 16 1 MED Digit1 (Scan1)
29 5
9 8 HI Digit0 (Scan0)
12V 30 4
IC01M Receiver SEG-a
31 3 TEMP UP TEMP DOWN MODE ON/OFF
ULN2004A
Buzzer SEG-b
CN-SYNC 32 2 SW7 SW5 SW4 SW6
LED out3 SEG-c
33 1
SYNC 3 3 RY-SYNC D07F D05F D04F D06F
34 35 36 37 38 39 40 41 42 43 44
MOTOR 1 1
ENERGY AUTO SWING

23
SAVER TIMER FAN

KEY1
VDD

KEY0
SEG-g
SEG-f
SEG-e
SEG-d
SW3 SW2 SW1 SW8
CN-4WAY

LED out2
LED out1
LED out0
SLIDE SW
D03F D02F D01F D08F
3 3 RY-4WAY 5V 17 5V
S/V- 1
4WAY 1 1
1 17
10 6
13 5
4.2 ELECTRONICS CONTROL DEVICE

CN-RD
RY-LOW 14 Digit0
4 Digit1
FAN CN-BL
MOTOR RY-MED a
R12F 1 16 R01G 150
CN-BK 6 12 5
RY-HI 20K a a
COOL
2 15 R02G 150 b
CAPACITOR C02F R02F C01F R01F 7 11 4
0.001 10K 0.001 10K A/SWING
5V R03G 150 DEFROST c b b
FAN 3 14 f f
8 10 3
R04G 150
A/RESTART DRY/HEAT
4 13 d
C R02E 9 9 2 g g
CN-WOR 20 TIMER
5 12 R05G 150
10 8 1 e
C01J R01E
0.1/275V 1K 6 11 R06G 150
FAN
11 7 e c e c
R01J
7 f
120 1/2W
E/SAVER g
7 10 R07G 150 AIR PURIFIER
HERM 6
IC01G 8 12 8
9 12V d d
ZNR01J ULN2004A
TVR14271 15 3
TVR14561
POWER TRANS 12V R01L
MAIN POWER 1 BZ01E 88 SEGMENT
4 7
5V 1K
1 D05D
COMP D02D IC01D IC02D 16 2 PKM13EPY
RY-COMP I O I O -4002
7805 Vcc 5V
G4A-1A-E-LG 7812 C01L +
D04D + + 680pF
CN-DISP CN-DISP
3 D03D + Vout C22L
2 4 C01D C02D C03D C04D C05D C06D
D02D~D05D 220
FUSE 1000 0.1 1000 0.01 220 0.01 GND
1N4004 10V
35V 50V 16V 50V 10V 50V
250V/T3.15A
RECEIVER
4.3 COMPONENTS LOCATION (OF MAIN P.C.B ASM)
MODEL : Micom Model (Cooling only Model)
- TOP VIEW

MODELS : Micom Models (Cooling only Models)

- BOTTOM VIEW

24
4.4 COMPONENTS LOCATION (FOR DISPLAY PCB) Micom Model

25
5. EXPLODED VIEW
554030

148000
130910

W48602

559010

149980

352390 349600
130410
346811

731273

554160

359012

354210 349480 550140

W52106-2 W52106-1
147582
W48602 349001

352115 552102

267110 352113

352111

135312 249950

263230
35211A

152302 W0CZZ
249950
135313
135303 268712 269310
237200

238310
135510
W0CZZ
137215
146812 135500
266002 146812
147581-2
149410 266003
268714
147581-1 264110
264110

26
6(A) REPLACEMENT PART LIST R: Service Parts
PART NO.
LOCATION NO. DESCRIPTION W121CA W123CA W123CM REMARKS
130410 BASE ASSEMBLY, SINGLE 3041AR1524G R
130910 CABINET ASSEMBLY,SINGLE 3091AR2286R R
135312 GRILLE ASSEMBLY,FRONT 3531A21002B R
135313 GRILLE.INLET 3530A20097A R
135500 COVER,CONTROL BOX 3550AR7032A R
137215 PANEL ASSEMBLY,CONTROL - 3720A10003A R
146812 MOTOR ASSEMBLY,SYNC. - R
147581-1 LOUVER,HORIZONTAL 5990A20036A R
148000 BRACE 4800A10001A R
149410 KNOB ASSEMBLY 4941A30025B 4941A30025B - R
149980 SHROUD 4998A23001A R
152302 FILTER ASSEMBLY,A/C 5231AR152A R
237200 PANEL ASSEMBLY,CONTROL 3721A23005A -
238310 ESCUTCHEON 3831A30030A - 3831A30030A R
249950 CONTROL BOX ASSEMBLY,SINGLE 4995A22007K 4995A22007G 4995A22007F R
263230 THERMISTER ASSEMBLY - - 6323A20003D R
264110 POWER CORD ASSEMBLY 2H00677S 2H00677G 2H00677G R
26602 SWITCH,ROCKER - R
266003 SWITCH,ROTARY 2H00598E 2H00598E - R
267110 REMOTE CONTROLLER - 6711A20056L R
268712 PWB(PCB) ASSEMBLY,DISPLAY - 6871A20643C R
268714 PWB(PCB) ASSEMBLY,MAIN - 6871A20188C R
269310 THERMOSTAT ASSEMBLY 2H01109H 2H01109H - R
346811 MOTOR ASSEMBLY,SINGLE 4681A20073D R
349001 DAMPER VENTILATION 4900AR7024A R
349480 ORIFICE 4948A10005A R
349600 MOUNT MOTOR 4960A23001A R
352102 TUBE CAPILLARY BEND 3H01535V R
352113 TUBE ASSEMBLY,DISCHARGE 5211A23055A R
352390 AIR GUIDE ASSEMBLY 5239AR1523J R
354210 EVAPORATOR ASSEMBLY,FIRST 5421AR2910D R
359012 FAN,TURBO 5900A24002A R
550140 ISOLATOR,COMP 4H00363A R
554030 CONDENSER ASSEMBLY,FIRST 5403A20083E R
554160 COMPRESSOR SET 5416A33001A R
559010 FAN,AXIAL 5900A24001B R
738281 MANUAL,SERVICE 3828A23007B R
738290 MANUAL,OWNERS 3828A36001B R
35211A TUBE ASSEMBLY, SUCTION 5211A23054A R
W0CZZ CAPACITOR 6120AR2194C R
W48602 CLAMP SPRING 3H02932B R
W52106-1 TUBE,EVAPORATOR 5210A33099A R
W52106-2 TUBE,EVAPORATOR 5210A33099B R
NOTE) *Please ensure GCSC since these parts may be changed depending upon the buyer's request.
(GCSC WEBSITE http://biz.LGservice.com)

27
6(B) REPLACEMENT PART LIST R: Service Parts

LOCATION NO. DESCRIPTION W091CA W093CA

130410 BASE ASSEMBLY, SINGLE 3041A23001B
130910 CABINET ASSEMBLY,SINGLE 3091A23002A
135312 GRILLE ASSEMBLY,FRONT 3531A23001A
135313 GRILLE.INLET 3530A23002A
135500 COVER,CONTROL BOX 3550A23002A
137215 PANEL ASSEMBLY,CONTROL -
146812 MOTOR ASSEMBLY,SYNC. -
147581-1 LOUVER,HORIZONTAL 5239A33001A
147582 LOUVER,VERTICAL 4758A23001A
148000 BRACE 4800A33001A
149410 KNOB ASSEMBLY 4941A20005A
149980 SHROUD 4998A23002A
152302 FILTER ASSEMBLY,A/C 5231A23002A
237200 PANEL ASSEMBLY,CONTROL 3721A23004A
238310 ESCUTCHEON -

249950 CONTROL BOX ASSEMBLY,SINGLE 4995A22007M

263230 THERMISTER ASSEMBLY -
264110 POWER CORD ASSEMBLY 2H00677P 2H00677G
26602 SWITCH,ROCKER -
266003 SWITCH,ROTARY 2H00598E
267110 REMOTE CONTROLLER -
268712 PWB(PCB) ASSEMBLY,DISPLAY -
268714 PWB(PCB) ASSEMBLY,MAIN -
269310 THERMOSTAT ASSEMBLY 2H01109L
346811 MOTOR ASSEMBLY,SINGLE 4681A20027B 4681A20027E
349001 DAMPER VENTILATION 4901A20003A
349480 ORIFICE 4948A23001A
349600 MOUNT MOTOR 4960A23002A
352102 TUBE CAPILLARY BEND 5210A23018K
352113 TUBE ASSEMBLY,DISCHARGE 5210A33607A
352390 AIR GUIDE ASSEMBLY 5239A23001E
354210 EVAPORATOR ASSEMBLY,FIRST 5421A20036C
359012 FAN,TURBO 5901A23001A
550140 ISOLATOR,COMP 4H00363B
554030 CONDENSER ASSEMBLY,FIRST 5403A20024F
554160 COMPRESSOR SET 5416A33006A 5416A33007B
559010 FAN,AXIAL 3828A36001B
738281 MANUAL,SERVICE 3828A23007B
738290 MANUAL,OWNERS 3828A36001B
35211A TUBE ASSEMBLY, SUCTION 5211A23302A
W0CZZ CAPACITOR 0CZZA20001W 6120AR2194H
W48602 CLAMP SPRING 3H02932B
W52106-1 TUBE,EVAPORATOR -
W52106-2 TUBE,EVAPORATOR 5211A29022A
NOTE) *Please ensure GCSC since these parts may be changed depending upon the buyer's request.
(GCSC WEBSITE http://biz.LGservice.com)

28
 January, 2005
P/No.: 3828A23007B Printed in India