LG EK-H2408C00 User manual

Single Packaged
Air Conditioner
SERVICE MANUAL
MODEL: EK-H2408C00

2Single Packaged Air Conditioner
Air Conditioner Service Manual
TABLE OF CONTENTS
Safety Precautions ............................................................................................................................3
Model Number Nomenclature ................................................................................................. 8
General Data ............................................................................................................................. 9
Dimensions............................................................................................................................. 10
Refrigerant Circuit diagram....................................................................................................11
Wiring Diagram....................................................................................................................... 12
Trouble Shooting Guide......................................................................................................... 13
Electric Parts Trouble Shooting Guide................................................................................. 17
Feature of Controller............................................................................................................. 24
Exploded View and Replacement Parts List........................................................................ 30

Service Manual 3
Safety Precautions
To prevent injury to the user or other people and property damage, the following instructions must be followed.
■Be sure to read before installing the air conditioner.
■Be sure to observe the cautions specified here as they include important items related to safety.
■Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following
indications.
■Meanings of symbols used in this manual are as shown below.
WARNING
CAUTION
This symbol indicates the possibility of death or serious injury.
This symbol indicates the possibility of injury or damage to properties only.
WARNING
■Installation
Be sure not to do.
Be sure to follow the instruction.
Safety Precautions
Do not use a defective or
underrated circuit breaker. Use
this appliance on a dedicated
circuit.
• There is risk of fire or electric
shock.
For electrical work, contact the
dealer, seller, a qualified
electrician, or an Authorized
Service Center.
• Do not disassemble or repair the
product. There is risk of fire or
electric shock.
Always ground the product.
• There is risk of fire or electric
shock.
Install the panel and the cover of
control box securely.
• There is risk of fire or electric
shock.
Always install a dedicated circuit
and breaker.
• Improper wiring or installation
may cause fire or electric shock
Use the correctly rated breaker
or fuse.
• There is risk of fire or electric
shock.

4Single Packaged Air Conditioner
Safety Precautions
■Operation
Use the specified wires to
connect the unit.
• There is risk of fire or electric
shock.
Do not install, remove, or re-
install the unit by yourself
(customer).
• There is risk of fire, electric
shock, explosion, or injury.
Be cautious when unpacking and
installing the product.
• Sharp edges could cause injury. Be
especially careful of the case edges
and the fins on the condenser and
evaporator.
For installation, always contact
thedealeroranAuthorized
Service Center.
• There is risk of fire, electric
shock, explosion, or injury.
Do not install the product on a
defective installation stand.
• It may cause injury, accident, or
damage to the product.
Be sure the installation area
does not deteriorate with age.
• If the base collapses, the air conditioner
could fall with it, causing property
damage, product failure, and personal
injury.
Do not let the air conditioner run for
a long time when the humidity is very
high and a door or a window is left
open.
• Moisture may condense and wet
or damage furniture.
Take care to ensure that power
cable could not be pulled out or
damaged during operation.
• There is risk of fire or electric
shock.
Do not place anything on the
power cable.
• There is risk of fire or electric
shock.
Do not plug or unplug the power supply
plug during operation.
• There is risk of fire or electric
shock.
Do not touch(operate) the
product with wet hands.
• There is risk of fire or electrical
shock.
Do not place a heater or other
appliances near the power cable.
• There is risk of fire and electric
shock.

Service Manual 5
Safety Precautions
Ventilate the product from time to time when
operating it together with a stove, etc.
• There is risk of fire or electric shock.
Turn the main power off when cleaning or
maintaining the product.
• There is risk of electric shock.
Do not allow water to run into
electric parts.
• It may cause There is risk of fire,
failure of the product, or electric
shock.
Do not store or use flammable gas
or combustibles near the product.
• There is risk of fire or failure of
product.
Do not use the product in a
tightly closed space for a long
time.
• Oxygen deficiency could occur.
When flammable gas leaks, turn
off the gas and open a window
for ventilation before turn the
product on.
• Do not use the telephone or turn
switches on or off. There is risk of
explosion or fire
If strange sounds, or small or smoke
comes from product. Turn the breaker
off or disconnect the power supply
cable.
• There is risk of electric shock or
fire.
Stop operation and close the window in
storm or hurricane. If possible, remove the
product from the window before the
hurricane arrives.
• There is risk of property damage,
failure of product, or electric
shock.
Do not open the panel of the product
during operation. (Do not touch the
electrostatic filter, if the unit is so
equipped.)
• There is risk of physical injury,
electric shock, or product failure.
When the product is soaked
(flooded or submerged), contact
an Authorized Service Center.
• There is risk of fire or electric
shock.
Be cautious that water could not
enter the product.
• There is risk of fire, electric
shock, or product damage.
Gasolin

6Single Packaged Air Conditioner
Safety Precautions
CAUTION
■Installation
Always check for gas (refrigerant)
pressure after installation or repair of
product.
• Low refrigerant levels may cause
failure of product.
Install the drain hose to ensure
that water is drained away
properly.
• A bad connection may cause
water leakage.
Keep level even when installing
the product.
• To avoid vibration or water
leakage.
Do not install the product where the noise or
hot air from the outdoor unit could damage
the neighborhoods.
• It may cause a problem for your
neighbors.
Don't use people to lift and
transport the product.
• Avoid personal injury.
Do not install the product where it
will be exposed to sea wind (salt
spray) directly.
• It may cause corrosion on the product. Corrosion,
particularly on the condenser and evaporator fins,
could cause product malfunction or inefficient
operation.
When the product is not be used for a long time,
disconnect the power supply plug or turn off the
breaker.
• There is risk of product damage or failure, or
unintended operation.
Take care to ensure that nobody could step on or
fall onto the unit.
• This could result in personal injury and product
damage.
90°
Having perfect vacuum process in the factory, our units don't have drier but have filter in the refrigerant circuit.
In case of recharging R-410A gas in the field,
"DRIER" must be installed on the liquid line which is connected from discharge part of condenser to intake
part of evaporator. Because the refrigerant circuit is capable of containing water with imperfect vacuum.

Service Manual 7
Safety Precautions
■Operation
Do not expose the skin directly to cool air for long
periods of time. (Don't sit in the draft.)
•This could harm to
your health.
Do not use the product for special purposes, such as preserving
foods, works of art, etc. It is a consumer air conditioner, not a
precision refrigeration system.
•There is risk of
damage or loss
of property.
Do not block the inlet or outlet of
air flow.
•It may cause product failure.
Use a soft cloth to clean. Do not
use harsh detergents, solvents,
etc.
•There is risk of fire, electric
shock, or damage to the plastic
parts of the product.
Do not touch the metal parts of the
product when removing the air filter.
They are very sharp!
•There is risk of personal injury.
Do not step on or put anything
on the product. (outdoor units)
•There is risk of personal injury
and failure of product.
Always insert the filter securely. Clean
the filter every four weeks or more
often if necessary.
• A dirty filter reduces the efficiency of
the air conditioner and could cause
product malfunction or damage.
Do not insert hands or other objects
through the air inlet or outlet while the
product is operated.
•There are sharp and moving parts
that could cause personal injury.
Wax
Thinner
Do not drink the water drained from the product.
•It is not sanitary and could cause serious health
issues.
Use a firm stool or ladder when cleaning or
maintaining the product.
•Be careful and avoid personal injury.

8Single Packaged Air Conditioner
Model Number Nomenclature
EK-H2408C00
1 2 3 4 5 6 7 8
A Changwon/R-410A
1 Manufacturing plant/Refrigerant E Turkey/R410A
K Turkey/R-22
L Changwon/R-22
2 Classification K Single packed Air Conditioner
N Ducted split Air Conditioner
3 Type C Cooling Only
H Heat pump
4 Capacity(Btu/h) 036(36000 Btu/h)~360(360000Btu/h)
8 380~415V, 50Hz, 3Phase
5 Voltage/frequency/phase 9 380V, 60Hz, ,3Phase
B 220V, 60Hz, 3Phase
D 440~460V, 60Hz, 3Phase
6 Air flow/Top Side C Convertible Air Flow(Down+Horizontal)
H Horizontal Air Flow
0 MICOM Control/10
7 Method/SEER A Mechanic Control/10
D Mechanic Control/13
8 Development Sequence Given Number by Delevelopment Sequence
Model Number Nomenclature

Nominal ton (Ton)
Models
Capacity Cooling Capacity (net) (Btu/hr)
(W)
(Kcal/h)
Heating Capacity (net) (Btu/hr)
(W)
(Kcal/h)
Electrical Data Voltage (V,PH)
M.C.A (with standard motor)
Cooling/Heating
(Amps)
Power Input
Cooling/Heating
(Watt)
Performance Air Circulation Nominal CFM CFM
EER (SEER)
Cooling/Heating
(Btu/hr.W)
Sound Rating Bell
Feature Wired Remote Controller
Time Delay Safety Function
Cooling Operation Mode
Heating Operation Mode (with E/Heater)
Soft Dry Operation
Timer setting (24-Hour on/off)
Auto Restart Mode
Humidifier Funtion
Test Function
Defrost
Hot Start
Self-Diagnosis Function
Phase Reversal Error Sensing
Phase Loss Sensing
Filter Type
Compressor Type
Quantity
Outdoor Coil Type
Tube Size (O.D) (inch)
(mm)
Row/FPI
Length (inch)
(mm)
Face area (sq.ft)
(m2)
Indoor Coil Type
Tube Size (O.D) (inch)
(mm)
Row/FPI
Length (inch)
(mm)
Face area (sq.ft)
(m2)
Outdoor Fan Type
No. Used/Diameter (in.)
Drive Type
CFM
No. Motor / Motor Output (Hp)
Motor RPM
Indoor Fan Type
No. Used
Diameter / Width inch/inch
Drive Type / Motor Step
No. Motors
Motor Output (standard / oversized) hp/hp
Motor rpm (standard / oversized) hp/hp
Drain Connection Size (in.)
Dimensions (WxHxD) (inch)
(mm)
Net Weight (kg)
(lbs)
20
EK-H2408C00
225,000
65,941
56,699
250,000
73,268
62,999
380~415V , 3PH
70
26,500/27,800
7,500
8.5/9.0
9.2
O
O
O
O
O
O
O
O
O
O
O
O
O
O
Washable & Anti-Fungus
Scroll
4
High Efficiency
9/32
7
3R / 17 FPI
78 3/4
2,000
41.59
3.86
High Efficiency
3/8
9.52
3R / 16 FPI
39 3/8
1,000
14.22
1.32
Propeller
4EA / 22
Direct
12,500
4/0.4
950
Centrifugal Blower Fan
1EA
18" / 18"
Belt/1
1EA
5Hp/7.5Hp
2,870~2,900 / 2,860~2,900
1
114 3/32*49 7/82*86 5/8
2,898*1,250*2,200
900
1,984
Service Manual 9
General Data
1) Test Condition of ISO Rated Cooling Capacity & Heating Capacity:
- Cooling : Ambient 95°F, Air Entering Temperature : 80.6°F DB and 6.2°FWB
- Heating : Ambient 44.8°F, Air Entering Temperature : 68°F DB and 59°FWB
General Data
2) Filters are standard supply.

10 Single Packaged Air Conditioner
Dimensions
Dimensions
J
K
H
M
N
L
I
CLEARANCE 34"
CLEARANCE 16"
CLEARANCE 34"
CLEARANCE 46"
F
E
H
G
A
B
C
D
CLEARANCE 34"
CLEARANCE 16"
CLEARANCE 34"
CLEARANCE 46"
HG
FE
ABCD
RETURN SUPPLY
TOP VIEW
UNIT Dimensions (Figure 1A)
Figure 1B
Figure 1C
Figure 1A
UNITS
H
I
J
K
L
M
N
49 7/32 (1250)
86 5/8(2200)
114 3/32 (2898)
73/32 (180)
48 13/32 (1230)
35/32 (80)
35/32 (80)
34 5/8(880)
17 5/8(448)
23 5/8(600)
331/32 (101)
75/32 (182)
39 3/8(1000)
51/8(137.5)
25 19/32 (650)
UNITS
A
B
C
D
E
F
G
H
HORIZONTAL FLOW APPLICATION (Figure 1B)
Unit: inch(mm)
Unit: inch(mm)
20RT
20RT
23 5/8(600)
15 5/8(396)
34 5/8(880)
611/16 (170)
64/8(165)
39 3/8(1000)
611/16 (170)
25 19/23 (650)
UNITS
A
B
C
D
E
F
G
H
DOWN FLOW APPLICATION (Figure 1C)
Unit: inch(mm)
20RT

Service Manual 11
Refrigerant Circuit Diagram
: Refrigerant Flow
CAPILLARY TUBE
2.0(I.D)*3EA
CAPILLARY TUBE
2.0(I.D)*1EA
CAPILLARY TUBE
1.8(I.D)*9EA
CAPILLARY TUBE
1.8(I.D)*9EA
3.36(I.D)*23EA
3.36(I.D)*23EA
OUTDOOR
COIL PRESSURE
CHECK PORT
PRESSURE
CHECK PORT
INDOOR
COIL
HI PRESSURE
SWTICH
LOW PRESSURE
SWTICH
CHECK
VALVE
CHECK
VALVE
Cooling Heating
ACCUM
CAPILLARY TUBE
2.0(I.D)*3EA
CHECK
VALVE
CHECK
VALVE
COMP
A-1
COMP
A-2
CAPILLARY TUBE
2.0(I.D)*1EA
PRESSURE
CHECK PORT
PRESSURE
CHECK PORT
HI PRESSURE
SWTICH
LOW PRESSURE
SWTICH
CHECK
VALVE
CHECK
VALVE
Cooling Heating
ACCUM
COMP
A-1
COMP
A-2
Refrigerant Circuit Diagram

12 Single Packaged Air Conditioner
Wiring Diagram
Wiring Diagram
EK-H2408C00
54 003399 19 Rev:a
3854U20290U

Service Manual 13
Troubleshooting Guide
PACKAGE AIR CONDITIONER VOLTAGE LIMITS
1. No cooling and heating operation performed
1) Both the blower and the compressor do not work
NAME PLATE RATING MINIMUM MAXIMUM
380~415V 342V 457V
2) Only Indoor blowers do not work
WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY
Other parts except the
unit
Magnetic Contactor for
compressor & fan motor
Operating switch
•Electric supply interrupted
•Defective power wiring
•Cut off power fuse
Too low voltage
Control point is on
condition of "OFF" due to
trouble.
Troubled or defective
contactor
Measure power sypply
with a tester in case that
the same power source is
supplied to other
equipment except the unit,
what and where troubled
can be discovered by
checking the operation of
other equipment.
Measure it with a tester.
Make short-circuit, then
measure it with tester.
Check it with the eyes or
tester.
•Repair a switch box
and relative instrument.
•Replacement of fuse
•Request a power
supplier to repair.
Check the power source.
Useathickcableif
necessary.
Replace it if necessary.
Repair or replace it.
WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY
Motor
Electric wiring
•Over heated
•Wiring short
•Cut- OFF of wiring
•Short circuited on
operation
Check it with tester
Check it with a tester.
Repair or replace it.
Rewiring or Repair.
Troubleshooting Guide

14 Single Packaged Air Conditioner
Troubleshooting Guide
3) Only outdoor fan does not work
WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY
Motor
Electric Wiring
Capacitor Defected Check it with tester. Replace it.
•Over-heated
•Wire short
Cut off of wiring
Short circuited on
operation
Check how it is insulated.
Check it with a tester.
Repair or replace it.
Rewiring or repair.
4) Only compressor does not work
WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY
Magnetic switch for
compressor motor
Compressor motor
High pressure switch
Electric circuit
Defective contact,
magnetic coil troubled.
Troubled over-heated
(layer short)
Troubled or defective
contact or operating
Defective connection or
disconnection of the circuit
for compressor.
Check it with the eyes on
with a tester.
Check how it is insulated.
Check it with a tester.
Check it with a tester.
Repair or replace it.
Replace or repair the
compressor.
Replace it if
necessary.
Rewiring or push
reset button.

Service Manual 15
Troubleshooting Guide
Note: Use an appropriate measuring instrument for readjustment.
*1: High-pressure switch moves.
*2: Low- pressure switch moves.
2. The Units discontinue after the operation started
WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY
Outdoor coil
In-condensable gas
blended.
High pressure switch
Refrigerant
Outdoor Fan
Coil is dirty *1
Air intruded into the
refrigerant pipe line *1
Improper adjustment
A shortage of refrigerant
amount. * 2
Check pressure
Reverse rotation of fan
Obstacle
Air short circuit *1
Checking
In the event that
difference between the
saturating temperature
corresponding to high
pressure and the
temperature of air
discharged from the
outdoor coil is more than
15°C, incondensable gas
may be blended.
Check it with a pressure
gauge.
Confirm the wind blowing
out upward.
Check it with eyes.
Wash it by means of
something like chemical
washing.
Extract air by vacuum
pump, then replenish
(charge) the refrigerant.
Read just it to normal
operating pressure.
(Note)
Don't alternate the
specified adjusting
pressure. If the adjusted
pressure exceed the
specified range, it will
cause a great accident.
Replenish the
refrigerant. Repair the
spot where it is leaked.
If reversed, connect
interchanged wires to
each terminal.
Power wirings.

16 Single Packaged Air Conditioner
Troubleshooting Guide
3. The unit is working, but not cooling and heating sufficiently
(Both blower and compressor are working)
WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY
Load
Air flow
Short air volume
Refrigerant
Air passage
Air filter
Much Cooling or Heating
load
Obstacle disturbs Intake
of uniform airflow.
Reverse rotation of
blower.
Shortage in the charged
refrigerant.
Improper or foreign bodies
Clogged with dust
Heat load increased.
Window or door has many
cracks or gaps.
Checking
Checking
Coil inlet pipe is frosted
Checking
Checking
Do necessary disposal
respectively.
Correct it.
Correct it.
Recharge it.
(Repair the leakage spot).
Correct or clear the
foreign bodies.
Cleaning
4.
All the functions are performed as specified, but very noisy and vibrant
WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY
Compressor
Blower
Screws
Electric troubles
(Magnetic contactor)
Others
•Checking
Checking
Checking
Checking
Improper installation Checking
•Replace the
compressor
Repair or replace it.
Clear the foreign bodies.
Correct
Repair and clean or
replace it.
Correct it.
Liquid refrigerant flooding
back from the evaporator.
Faulty Discharge valve
and suction valve.
Fan broken.
Foreign matters intruded.
Looseness or fail-off of
screws
Defective contact.
Defective contact point.
Rusting and foreign
matters in the iron core
contact face. Defective
contact of the
operating switch.
•Check for refrigerant over-charge.
•Check to see if the intake air temperature is
extremely cold.
•Check for insufficient air flow quantity.

Service Manual 17
Electronic parts Troubleshooting Guide
YES
YES
NO
Is the input voltage of
Main PCB AC220V?
1. Check the Fuse.
2. Check the wiring of AC220V.
Is the output voltage
of IC03D(7812 ) on the
main PCB DC5V?
OSC01B vibration?
1. Exchange main PCB ASS'Y
1. Exchange remote-controller
2. Check or exchange the Main
PCB ASS'Y.
YES
NO
NO
YES
Is the output voltage
of IC01A(7036) on the
main PCB DC5V?
NO
1. Exchange IC03D(7805) on
the main PCB.
1. Exchange IC01A(7036) on
the main PCB.
1. Exchange OSC01B.
2. Check the pattern around
OSC01B on the main PCB.
Is the input voltage
of remote-controller
DC12V?
YES
NO
YES
Is the power ON?
NO
1. Check the FUSE.
2. Check the input voltage of
Main PCB ASS'Y.
1. Check or exchange the IC03D
on the Main PCB.
2. Check or exchange the
Connector (RED, BROWN)
of the remote controller.
Possible trouble 1 : The unit does not operate.
Possible trouble 2 : The remote-controller does not operate.
Electronic parts Troubleshooting Guide

18 Single Packaged Air Conditioner
Electronic parts Troubleshooting Guide
YES
NO
YES
NO
NO
Is the connection between
MAIN PCB and remote-controller
correct?
Is there Check(F**) on
the remote controller LCD?
1.
Check or repair Connector wiring.
2. Exchange the Connector.
Is the input power voltage of
remote-controller DC12V?
Do Keys have troubles?
Exchange remote-controller.
Exchange remote-controller.
NO
YES
1. Replace the pressed key.
2. Exchange the Knob or Key.
YES
NO
1. Remove cause of Check.
YES
YES
Is there OSC01B vibration
on the remote-controller
PCB?
NO
1. Check 220V Power on the
MAIN PCB.
1. Exchange OSC01B
2. Check the pattern around OSC01B
on the remote-controller PCB.
Is any key on the remote-controller
keeping pressed?
1. Check Keys.
2. Repair or exchange Key.
Is there trouble in the
remote-controller PCB
ASS'Y?
NO
YES
NO
Are there trouble in
LCD parts?
YES
1. Check crack, damage of LCD.
2. Check LCD pattern.
1. Check or repair all IC with
dust or moisture on the PCB.
2. Exchange remote-controller
PCB.
Possible trouble 3 : Key input of remote-controller does not respond.
Possible trouble 4 : LCD display on the remote-controller shows some trouble.

Service Manual 19
Electronic parts Troubleshooting Guide
YES
YES
YES
NO
YES
Is the cooling mode?
Is the output
voltage of IC03D on the MAIN
PCB DC5V?
1. Press cooling operation key.
2.
After reenergizing power supply,
press power "ON/OFF" button.
YES
NO
Is the unit operating? 1. Press power ON/OFF button.
Is the output
voltage of IC01M's 11,12(COMP B)PIN
on the MAIN PCB DC0V?
Is the magnetic contactor
for compressor ON?
1. Check Compressor and
Capacitor for Compressor.
NOTE: 3ømodel has not capacitor for compressor.
YES
NO
1. Set following.
'Set Temp. < Room Temp.'
NO
NO
1. Check or exchange IC03D
on the MAIN PCB.
NO
YES
Is the voltage
between A/B(COMP B) of CN-COMP
and NEUTRAL 220V?
NO
1. Check or exchange IC01M.
2. Check 3-minutes time delay.
1. Check or exchange RY4/RY5(COMP B).
Set Temp. < Room Temp.?
1. Check the wiring of Magnetic
contactor.
2. Exchange Magnetic contactor.
Possible trouble 5 : No cooling operation performed.

20 Single Packaged Air Conditioner
Electronic parts Troubleshooting Guide
Is the heater LCD "ON"?
Is the output
voltage of IC03D on the
MAIN PCB DC5V?
1. Reconnecting power supply.
Press Heater Key.
Is the heater operation? 1. Select heater operation mode.
Is the output
voltage of IC02M's 15, 16PIN on the
MAIN PCB 0V?
Is the magnetic contactor for
heater ON?
Check or exchange E/Heater.
1. Set following.
'Set temp. > Room temp.'
1. Check or exchange IC03D,
IC02D on the MAIN PCB.
Is the voltage
between A/B(Heat B) of CN-HEAT
and NEUTRAL 220V?
1. Check or exchange IC02M.
1. Check or exchange RY13/RY14(Heat A, B).
Set temp. > Room temp.?
1. Check the wiring of Magnetic
contactor.
2. Exchange Magnetic contactor.
YES
YES
YES
NO
YES
YES
NO
YES
NO
NO
NO
NO
YES
NO
Possible trouble 6 : No heater operation performed.