REFRIGERATOR SERVICE MANUAL
Contents
1. NOTE 1 The shape of parts are subject to change in different localities Optional parts 16 LG Electronics Inc P NO 3828JD8401A2. U and screw it into the opposite side hole After refitting the door fix the Lower Hinge L in the opposite side by using 2xBOLTS Fix the Leg Carefully place the appliance in an upright position Adjust the Leveling screw to make sure the appliance is steady and check that the door opens and closes properly Figure 6 4 COMPONENTS 1 COMPRESSOR 1 Role The compressor intakes low temperature and low pressure gas evaporated from Evaporator of the Refrigerator and condenses this gas to high temperature and high pressure gas and then plays delivering role to Condenser 2 Composition The Compressor is Composed of Compressor Apparatus compressing gas Compressor Motor moving Compressor Apparatus and Case protecting Compressor Apparatus and Motor There are PTC Starter and Over Load Protector OLP in the Compressor outside On the other hand because the Compressor consists of 1 1000mm processing precision components and is sealed after production in absence of dust or humidity deal and repair with care 3 Note for Usage 1 Be careful not to allow over voltage and over current 2 No Strike If applying forcible power or strike dropping or careless dealing poor operation and noise may occur 3 Use proper electric components appropriate to the Compressor 4 Note to Keep Compressor If Compressor gets wet in the rain and rust in the pin of Hermetic Terminal the re
3. container to prevent dust 2 Fluoridation kalium 35 putting in the FLUX Water 4 e Keep it in a stainless steel container Mix the above ingredients and boil until they are transformed into liquid LOKRING 1 Both of the tube is inserted up to the stop e For a hermetically sealed metal metal Figure 15 16 2 Both of the LOKRING is pushed up to the stop connection the tube ends have to be clean 3 The bending point is not too close to the e LOKPREP is distributed all of out surface of 3 joint ending the tube ends 4 During the assembly it is important that both ends remain completely within the joint DRIER 1 Assemble the drier within 30min e Don t keep the drier in a outdoors because ASM after unpacking humidity damages to it 4 2 Keep the unpacked drier at the temperature of 80 100 C VACUUM 1 When measuring with pirant Vacuum e Apply M C Vacuum Gauge without fail gauge the charging M C vacuum e Perform vacuum operation until a proper degree is within 1 Torr vacuum degree is built up 2 If the vacuum degree of the cycle inside is e If a proper vacuum degree isn t built up 10 Torr below for low pressure and 20 Torr check the leakage from 5 for high pressure it says no vacuum the Cycle Pipe line part and leakage state Quick Coupler Connecting part 3 Vacuum degree of vacuum pump must be 0 05 Torr below after 5 min 4 Vacuum degree must be same to the value described item 2 above for more than 20 min DRY A
4. oo Compressor Motor Replace the Compressor Check the resistance of Test the resistance of the both 339 20 the PTC terminals in the PTC STARTER Replace the PTC STARTER Advice the customer to use in the specified range Check if applying a regular OLP Replace OLP Measure minimum starting voltage Check the starting after checking steps 1 3 above Starts at the voltage Normal state Measure the pressure balance of the of 85 below PTC at the interval of more than 5 min Check the starting state at the regular voltage above Replace the PTC PTC First separate the PTC from the Compressor and check the voltage between NO 5 and 6 in the PTC with a multitester or Wheatstone Bridge Poor starting or no operating of the Compressor Observation value is Check another 220 240V 50Hz electric 332 20 components The value is 0 Replace the PTC yes Check other electric Separate the OLP from the Compressor and check components resistance value between two terminals of OLP with Tester NO Replace OLP 10 ANOTHER ELECTRIC COMPONENTS Y No Cooling The Compressor Check if the current flows P i i Replace the oor contacting point doesn t run at the contacting point of Thermostat the Thermostat Check the current flowing Shorted or Broken Replace the device of starting system Check if the current flows F Replace the at the main coil of the Coil shorted
5. the back wall of fridge room 1 SPECIFICATIONS 1 1 GR 154 ITEMS SPECIFICATIONS ITEMS SPECIFICATIONS FREEZER 100 DRAWER 4EA STORAGE CAPACITY TOTAL 100 ICE TRAY YES DIMENSIONS mm 550 W X 600 D X 850 H COMPRESSOR P T C Starting Type NET WHIGHT kg 40 CONDENSER Wire Condenser TEMPERATURE CONTROL BUTTON REFRIGERANT R600a 40g DEFROSTING SYSTEM MANUAL OUT CASE Coated Steel sheet INNER CASE ABS INSULATION CYCLOPENTANE LUBRICANT OIL 2 PARTS IDENTIFICATION HTS 60 MT 210cc Freezer Drawer Leveling Screws NOTE This is a basic model The shape of refrigerator is subject to change Magnetic gasket 3 DISASSEMBLY 2 PRECAUTION 1 First unplug the appliance 2 Remove foods and accessories like shelves or trays which are not fixed in the refrigerator 3 Carefully lay the appliance on a cushion like packing material to avoid the damage of refrigeration circuit 4 Use driver or spanner to fix or remove the bolts Remove the LEG Reversible 4 a o N Before refitting the door swap the Hinge Cap by pulling it out from its current location and repositioning it on the other side of the door Care should be taken not to damage the adjacent surfaces when removing the Hinge Cap Unscrew the Upper Hinge pin
6. COMPRESSOR DOSE NOT COMPRESS NOISY MOTOR COMPRESSOR No frost forms on the evaporator even if the motor compressor is running In case of mechanical failure in the motor compressor there in an excessive noise when the system is functioning In case a suspension spring is unhooked banging will be heard and there will be especially strong vibrations when the system starts up and stops In this case there is a mechanical failure in the diaphram valves which remaining continually open do not permit the compressor to operate Consequentely isobutane does not circulate in the system The cause of the excessive noise is normally to be sought for in a mechanical breakdown and only rarely in the unhooking of one of the suspension springs 12 The motor comprossor must be replaced and then proceed with refilling The motor compressor must be replaced and then proceed with the refilling Y General Control of Refrigerating Cycle NO ITEMS CONTENTS AND SPECIFICATIONS REMARKS WELDING 1 H 30 ROD e Chemical Ingredients e Recommend H34 containing 34 Ag in the Ag 30 Cu 27 Zn 23 Cd 20 Service Center Brazing Temperature 710 840 C 1 2 Bcup 2 e Chemical Ingredients Cu About 93 P 6 8 7 5 The rest within 0 2 e Brazing Temperature 735 840 C FLUX e Ingredients and how to make e Make amount for only day Borax 30 Holding period 1 day Borax 35 e Close the cover of
7. Comprossor Check the components Replace the on the main circuit components Poor running of the Compressor Measure the starting voltage Increase the voltage Low voltage Check if the current flows Shorted Poor contacting Replace the device at the contacting point of point and broken the starting system Frost doesn t form on the Refrigerant leaks Poor Repair the Compressor back wall of freezer and no P P fridge room when operating set for more than 30 min 11 REFRIGERATING CYCLE Y Troubleshooting chart DEFECT EFFECT CAUSE REMEDY SYSTEM PARTIALLY OR COMPLETELY OUT OF REFRIGERANT CHARGE EXCESSIVELY FULL Freezer and fridge room do not frost even though motor compressor runs continually This defect is indicated by the presence of water outside the refrigerator near the motor caused by formations of ice on the return tube An empty refrigerant system indicates a leakage of isobutane R600a This loss is generally to be looked for at the soldering points connecting the various components or in an eventual hole in the evaporator made by the user If in the refrigerant system a quantity of R600a is introduced which is greater than that indicated the excess gas does not terminate ts expansion in the evaporator but proceeds into the return tube Leakage must be eliminated by resoldering the defective point The system must be emptied and subse
8. Cycle and PTC cooling 2 During normal operation of the Compressor Motor PTC elements generate heat continuously Therefore if PTC isn t cooled for a while after the power has been shut off Motor can t operate again 5 Relation of PTC Starter and OLP 1 If the power is off during operation of Compressor and the power is on before the PTC is cooled instant shut off within 2 min or reconnect a power plug due to misconnecting the PTC isn t cooled and a resistance value grows As a result current can t flow to the sub coil and the Motor can t operate and the OLP operates by flowing over current in only in the main coil 2 While the OLP repeats on and off operation about 3 5 times PTC is cooled and Compressor Motor performs normal operation IFOLP doesn t operate when PTC is not cooled Compressor Motor is worn away and causes circuitshort and fire Therefore use a properly fixed OLP without fail 6 Note to Use PTC Starter 1 Be careful not to allow over voltage and over current 2 No Strike Don t apply a forcible power or strike 3 Keep apart from any liquid If liquid such as oil or water away enter the PTC PTC materials it may break due to insulation breakdown of the material itself 4 Don t change PTC at your convenience Don t disassemble PTC and mold If the exterior to the PTC starter is damaged resistance value is altered and it may cause poor starting of the compressor motor may cause 5 Use a
9. ND 1 The pressure of dry air must be more AIR han 12 16kg cm2 6 NITROGEN 2 a must be more than GAS 3 Keep the pressure at 12 6kg cm also when substituting dry air for Nitrogen Gas NIPPLE 1 Check if gas leaks with soapy water e Check if gas leaks from joint of the 7 AND 2 Replace Quick Coupler in case of leakage Coupler COUPLER PIPE e Put all Joint Pipes in a clean box and 8 cover tightly with the lid so that dust or humidity is not inserted 13 LOKRING ne LOKRING JOINT Figure 15 LOKRING Figure 16 LOKRING TOOL 14 5 EXPLODED VIEW NOTE 1 The shape of parts are subject to change in different localities
10. REFRIGERATOR CAUTION BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL MODEL GR 154 COLOR SUPER WHITE CONTENTS Page SAFETY PRECAUTIONS 4 2 RE anglais 2 SERVICING PRECAUTIONS ZIEL nal 3 SPECIFIGCATIONS a naeh a a a na an aan an nn kn 4 PARTS IDENTIFICATION ER 4 DISASSEMBLY A ANTS 5 6 DOOR EERE ERE EENES IATE REA ORTE ete an a ance RRA tii 5 FREEZER DOOR icc ieee A A ins Ra elas aeons een ei ean eevee adic 5 TOR T BEESE ne he et a dt AAA atte Inds 6 FREEZER DOOR HANDLE Ma isa sa AA a aan ite nian 6 TAERMOSTA TNA Nikkei 6 COMPONENTS a iia 7 8 CIRCUITS DIAGRAM 2 2 2 A fe 8 TROUBLESHOOTING 2 2 22 32 22 A eee Rei 9 10 ANOTHER ELECTRIC COMPONENTS 222 ue2244220220000000000000n000nnnnnnnnunnunnnnnnnnunnnnnnnnunnnnnnnnnnnnnnnnennnnnnnnnnnunnnnnnennnn nme 11 REFRIGERATING CYCLE iii Li 12 13 EXPLODED VIE W increas aAA ASA lucas AEA EL oa paid 15 16 REPLACEMENT PARTS LIST 22 22 2 A ee 17 Please read the following instructions before servicing your 7 When tilting the set remove any materials on the set refrigerator especially the thin plates ex Glass shelf or books 1 Check the set for electric losses 8 Leave the disassembly of the refrigerating cycle to a 2 Unplug prior to servicing to prevent electric shock specialized service center The gas inside the circuit may 3 Whenever testing with power on wear rubber gloves to
11. or replacing any part in the cycle No Fire No Welding Connect the Schrader valve to pump with the coupler And then turn the pump on for vacuum state Figure 3 Let the pump run until the low pressure gauge indicates the vacuum gauge pressure 0 absolute pressure 1atm or 760mmHg Recommended vacuum time is 30 min Charge the N2 gas in order to check for leakage from welding points and the LOKRING If leakages are found repair the defects and repeat the vacuum process Figure 3 After the system is completely vacuumed fill it with the refrigerant R600a up to what has been specified at your refrigerator Name Plate The amount of refrigerant R600a must be precisely measured within the error of 1g by an electron scale Figure 4 If you use the manifold connected with both the refrigerant R600a cylinder and the vacuum pump simultaneously make sure the pump valve is closed Figure 5 REFRIGERANT R600a 7 CHARGING HOSE COUPLE THROTTLE VALVE Figure 4 WEIGH SCALE FILLING OR VALVE TO BE OPENED CHARGE TUBE WHEN REFILLING QJ ee TO THE TO THE CHARGE REFRIGERATION HOA g SYSTEM VALVE TO BE CLOSED AFTER VACUUM i TO THE VACUUM PUMP Figure 5 Connect the charging hose that is connected to the refrigerant R600a cylinder to POINT TO BE CHARGE TUBE BROKEN es SCHRADER VALVE ONE WAY VALVE SERVICE TUBE EXTENSION LOKRING Figure 1 Figure 2 Attach the service t
12. pollute the environment prevent electric shock 9 When you discharge the refrigerant wear the protective 4 If you use any kind of appliance check regular current safety glasses or goggle for eye safety voltage and capacity 10 When you repair the cycle system in refrigerator the work 5 Don t touch deep frozen products in the freezer with wet area is well ventilated hands This may cause frostbite Especially if the refrigerant is R600a there are no fire or 6 Prevent water from following onto electric elements in the heat sources No smoking mechanical parts SERVICING PRECAUTIONS Features of refrigerant R600a Achromatic and odor less gas Flammable gas and the ignition explosion at 494 C e Upper lower explosion limit 1 8 8 4 Vol Features of the R600a refrigerator Charging of 60 refrigerant compared with a R134a model The suction pressure is below 1bar abs during the operation Because of its low suction pressure the external air may flow in the cycle system when the refrigerant leak and it causes malfunction in the compressor The displacement of compressor using R600a must be at least 1 7 times larger than that of R134a e Drier type is XH 9 The EVAPORATOR or any other cycle part that has welding joint is hidden in the foam If not hidden inside the whole electric parts must be tested with the LEAKAGE TEST according to the IEC Standard The compressor has label of the refrigeran
13. properly fixed PTC Te 3 OLP OVER LOAD PROTECTOR 1 Definition of OLP 1 OLP OVER LOAD PROTECTOR is attached to the aa Hermetic Compressor and protects the Motor by POIN ee cutting off current in Compressor Motor in case of over rising temperature by Bimetal in the OLP 2 When over voltage flows to Compressor motor the Bimetal works by heating the heater inside the OLP and the OLP protects Motor by cutting off current which flows to the Compressor Motor 2 Role of the OLP 1 The OLP is attached to the Hermetic Compressor used for the Refrigerator and Show Case and prevents the Motor Coil from being started in the Compressor 2 Do not turn the Adjust Screw of the OLP in any way for normal operation of the OLP Composition and connection Diagram of OLP BIMETAL Figure 12 HEATER 4 CIRCUIT DIAGRAM OVER LOAD PROTECTOR ne P T C STARTER THE PLUG TYPE ON CIRCUIT DIAGRAM IS SUBJECT TO CHANGE IN DIFFRENT LOCALITIES COMPRESSOR 3854JS1001N TROBLESHOOTING COMPRESSOR AND ELECTRIC COMPONENTS y Equal to the applied P Ss Separate the PTC STARTER from the f D Compressor and measure the voltage voltage Rating between M and C of the Compressor voltage 10 The applied voltage is not in the range Advice the customer to of Rating Voltage 10 use In ineispecimed range Check the Test the resistance among resistance of the M C S C and M S If not O or
14. quently refilled introducing the correct quantity of R600a HUMIDITY IN THE SYSTEM This defect is indicated by the partial frosting of the freezer room and by continual defrosting cycles determined by the interruption of the flow of gas on the evaporator The motor compressor keeps running The refrigerant system is humid when there is a small percentage of water present which not completely retained by the dehydrator filter enters into circulation with isobutane and freezes at the capillary exit in the evaporator The system must be emptied and then refilled after eliminating the humidity PRESENCE OF AIR IN THE SYSTEM Poor performance of the refrigerant system which is indicated on the evaporator with a slight frost which does not freeze and an excessive overheating of the condenser and motor compressor There is air in the refrigerating system when during the filling phase vacuum is not effected or it is not adequately done Group must be drained and subsequently refilled after carefully creating vacuum BLOCKED CAPILLARY Because of the lack of circulation isobutane in the system there is no frosting of the evaporator while a slight overheating of the first spiral of the condenser is noted Impurities contained in isobutane or in the components of the refrigeration system before assembly and not retained by the filter can obstruct the capillary Do away with the refrigerator MOTOR
15. sult may be poor operation and poor contact may cause 5 Be careful that dust humidity and flux welding don t inflow in the Compressor inside in replacing the Compressor Dust humidity and flux due to welding which inflows to Cylinder may cause lockage and noise 2 PTC STARTER 1 Composition of PTC Starter 1 PTC Positive Temperature Coefficient is a no contact semiconductor starting device which uses ceramic material and this material consists of BaTiO3 2 The higher the temperature is the higher becomes the resistance value These features are used as starting device for the Motor 2 Role of PTC Starter 1 PTC is attached to Hermetic Compressor used for Refrigerator Show Case and starts Motor 2 Compressor for household refrigerator applies to single phase induction Motor For normal operation of the single phase induction motor in the starting operation flows in both main coil and sub coil After the starting is over the current in subcoil is cut off The proper features of PTC play all the above roles So PTC is used as a motor starting device 3 PTC Applied Circuit Diagram According to Starting Method for the Motor OVERLOAD PROTECTOR O L P COMPRESSOR MOTOR HERMETIC TERMINAL PTC STARTER Figure 11 4 Motor Restarting and PTC Cooling 1 For restarting after power off during normal Compressor Motor operation plug the power cord after 5 min for pressure balance of Refrigerating
16. t R600a Only the Service man must have an access to the system Installation place e Must be well ventilated e Must be 20 m or larger e Must be no smoking area No ignitable factors must be present Utilities e Refrigerant cylinder MAX NET 300g e Manometer e Vacuum pump 600L min e Piercing Clamp Quick coupler e Hoses 5m 1EA 1m 3EA e LOKRING Portable Leakage detector 3g year Nitrogen cylinder for leakage test e Concentration gauge Make sure before Servicing Refrigerant Confirm the refrigerant by checking Name Plate on innerliner and the label on the compressor If the refrigerant is R600a you must not weld or apply a heat source Air Recharging in Compressor Before refilling the refrigerant you must perform the test according to Chapter 5 TROUBLESHOOTING CHART When the defects are found you must discharge the residual refrigerant R600a in the outdoor For discharging the refrigerant R600a break the narrow portion of tube extension by hand or with a pipe cutter as shown in Figure 1 Leave it for 30min in outside to stabilize the pressure with ambient Then check the pressure by piercing the dryer part with piercing pliers If the refrigerant is not completely discharged let the refrigerator alone for more 30min in outside After the refrigerant R600a is completely discharged repair any defective parts and replace the dryer At any case you must use the LOKRING for connecting
17. ube installed with a Schrader valve one way valve by using the LOKRING Figure 2 Then connect the Schrader valve one way valve to the pump that is connected to the discharging hose leading to the outside When discharging the residual refrigerant repeat 3 cycle that includes 3min of the pump running gt pump off gt 30sec of the compressor running the Schrader valve installed on the service tube Then charge the refrigerant R600a by controlling the Throttle valve When you do so do not fully open the Throttle valve because it may make damage to the compressor Gradually charge the refrigerant R600a by changing open and close the Throttle Valve 5g at each time The charging hose must use a one way valve to prevent the refrigerant refluence Close the Schrader valve cap after the refrigerant R600a is completely recharged After you completely recharge the refrigerant R600a perform the leakage test by using a portable leakage detector or soapy water Test the low pressure suction parts in compressor off time and high pressure parts in compressor on time If the leakages are found restart from the refrigerant R600a discharging process and repairs defects of leaks After the leakage test check the temperature of each parts of the cycle Check with hands if the CONDENSER and the case HOT LINE pipe that is contacted to the door gasket are warm Confirm that frost is uniform distributed on the surface of the freezer room and
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