LG GCS165SVB Owner's manual

LG GCS165SVB Owner's manual
http://biz.lgservice.com
CHEST FREEZER
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE UNIT, READ
THE "SAFETY PRECAUTIONS" IN THIS MANUAL.
MODEL: GCS165SV
COLOR: PCM-Super White
CONTENTS
(Page)
SAFETY PRECAUTIONS ............................................................................................................................................................. 2
SERVICING PRECAUTIONS ....................................................................................................................................................... 3
SPECIFICATIONS .......................................................................................................................................................................... 4
DISASSEMBLY ................................................................................................................................................................................ 6
THERMOSTAT................................................................................................................................................................................ 6
HANDLE ........................................................................................................................................................................................ 6
DOOR .............................................................................................................................................................................................. 6
ADJUSTMENT
............................................................................................................................................................................ 7
CIRCUIT DIAGRAM ..................................................................................................................................................................... 8
TROUBLESHOOTING ................................................................................................................................................................... 9
COMPRESSOR AND ELECTRIC COMPONENTS .............................................................................................
.............................................................................................. 10
PTC .............................................................................................. ................................................................................................... 11
OTHER ELECTRIC COMPONENTS ........................................................................................................................................... 12
EXPLODED VIEW .... . .................................................................................................................................................................. 13
SAFETY PRECAUTIONS
Please read the following before servicing your
refrigerator.
AIR RECHARGING IN COMPRESSOR
Test the refrigeration system by connecting it electrically before
beginning the refilling operation. This is necessary to ascertain
the function of the motor-compressor and identify defects
immediately. If defects have been found, empty the old system
of R134a residue by breaking off the end of the extension piece
at its narrow point.
(Figure 1) Use the appropriate refrigerant recovery equipment.
Replace the filter and any damaged components. Unsolder and
pull off the piece remaining inside the service tube and then
attach an extension with male Hansen, and last, solder it to the
same tube again. (Figure 2)
1. Check if electric leakage occurs in the set.
2. When servicing current applying parts, unplug prior to
servicing.
3. If testing with power on, wear rubber gloves to prevent
electric shock.
4. Be sure to check regular current, voltage, and capacity.
5. Don't touch metal products in a cold freezer compartment
with wet hands. It may cause frostbite or other injury.
6. Prevent water flowing to electric elements in mechanical
parts.
7. When tilting the set, remove any materials on the set,
especially thin plate type (ex,: glass plates or books.)
8. Do not open the sealed refrigeration system. It could
cause injury or pollute the air. Leave this job to an
autherized servicer with the appropriate refrigerant
recovery equipment.
9. Curatorial, combustible, explosive, corrosive and volatile
goods cannot be stored in the chest freezer.
10. Turn off the power and open the door, take the goods to
make defrosting when frost thickness is more than 5mm.
Acuate or hard tools are not allowed to make defrosting.
11. Chemic reagent is not allowed when washing the chest
-2freezer. Pls clean it both inside and outside with soft cloth
in litmusless soap water or abluent.
POINT TO BE
BROKEN
CHARGE TUBE
EXTENSION
FEMALE
HANSEN
MALE
HANSEN
SERVICE TUBE
EXTENSION
Figure 1
SOLDERING
POINT
Figure 2
SERVICING PRECAUTIONS
It is necessary to execute the soldering operation with valve
open so that the fumes caused by oil residue can come out
freely without blowholes between two tubes during heating the
point to be soldered.
The extension fitted with the male Hansen is connected to the
female fitting of the vacuum pump tube. (Figure 3) Air
evacuating from the system begins as soon as the pump starts.
The refrigeration system must be kept under vacuum until the
reading on the low-pressure gauge indicates vacuum (0
absolute, -1 atm., -760 mm hg.) In any case, it is advisable to
keep the pump running for about 60 minutes. (Figure 4)
TO THE
VACUUM
PUMP
PRESSURE
GAUGE
Figure 3
If case that a considerable leakage occurs, it will be necessary
to stop the vacuum pump and add a small quantity of Freon to
the system, if vacuum should not be obtained (pressure gauge
doesn't fall to 1 atmosphere.) Start the refrigeration unit and
find the leakage with a special leak-finder. When the defective
soldering point is visible, repair it after opening the extension
tube valve and reestablishing the normal outside pressure
inside the system.
Because the melted solder is sucked into the tubes and blocks
them, the pressure must be rebalanced when vacuum is in the
system for soldering. As soon as the vacuum operation is over,
add the quantity (in grams) of R134a to the refrigeration
system. Remember that every system has an exact quantity of
R134a with a tolerance of ±5 grams than can be added.
(Figure 5)
TO THE
R-134a CYLINDER
TO THE
REFRIGERATION
SYSTEM
Figure 4
Before performing this operation (if the vacuum pump and
refilling cylinder are connected), make sure that the valve
placed between the vacuum pump and refilling tube are closed
to keep the Freon from adding to the system.(Figure 6)
In addition, check the graduated scale on the cylinder for the
quantity of R134a to be added; for example, if we have 750
grams of Freon in the cylinder and must add 165 grams to the
group, this amount will be reached when R134a has dropped to
585 grams, remembering that the indicator shows a lower limit
of meniscus. Do this after choosing the scale corresponding to
the gas pressure different scales reported as the same gas
pressure indicated by the pressure gauge on the top of the
column.
To make R134a flow into the system, open the valve placed at
the base of the cylinder and connected to the filling tube. The
amount of Freon cannot be added to the system all at once
because it may cause a blocking of motor-compressor.
Therefore, proceed by adding original quantity of about 20-30
grams and close the valve
immediately thereafter.
The pressure rises and the motor-compressor must start,
sucking the gas and making the pressure go down again.
Regulate the valve again, maintaining the same manner until
reaching the quantity of R134a established for the system being
charged. When the system is running, the suction pressure
must be stabilized from 0.10 to 0.4 atmosphere.
-3-
FILLING OR
CHARGE TUBE
TO THE
REFRIGERATION
SYSTEM
TO THE
VACUUM
PUMP
Figure 5
VALVE TO BE
OPENED WHEN
REFILLING
TO THE
CHARGE
CYLINDER
VALVE TO BE
CLOSED
AFTER VACUUM
SPECIFICATIONS
Ref. No: GCS165SV
ITEMS
SPECIFICATIONS
ITEMS
SPECIFICATIONS
DIMENSIONS (mm)
Capillary
Φ0.8
NET WEIGHT (kg)
Drier
molecular siever
LOCK ASSEMBLY
1 EA
Cover Glass
1 EA
COOLING SYSTEM
Direct Cooling
TEMPERATURE CONTROL
Knob Dial
DEFROSTING SYSTEM
Heater Defrost
Heat preservation
Cyclopentane
COMPRESSOR
PTC Starting Type
EVAPORATOR
Fin Tube Type
Manual,assembly owners (1EA)
Manual owners (1EA)
Card, warranty (1EA)
Key (2EA)
CONDENSER
REFRIGERANT
R134a(90 g)
Lock
Door
Decor, cover
Machine room
Leg Adjust
Thermistor
-4-
DISASSEMBLY
I. Instruction for removal of the temperature control component
1. Removal of the temperature control component:
hold the fixture on the upper part of the temperature
control panel to push the temperature control
component outwards the case from the compressor
cabinet; hold and lift upwards the top of the
temperature control panel to remove the temperature
control component from the case after pushing.
2. Removal of the temperature control knob:
pull the temperature control knob from the
temperature controller directly.
3. Removal of the temperature controller:
Remove the screw which is used to fix the case controller
and controller panel , separate these 2 parts. Loose and
remove the temperature controller fix nut with Φ15mm sleeve,
6
4. Removal of the indicator lamp:push aside the clamped hook a little ,
pull the indicator lamp outwards and remove it
II. Instruction for removal of the hinge components
1. Removal of the upper housing of the hinge: slightly
move the upper housing of the hinge outwards, and lift
upwards to remove.
2. Removal of the lower housing of the hinge: slightly
move the lower housing of the hinge outwards, and
push downwards to remove.
3. Removal of the hinge: screw off the screws for fixing
the hinge with the pneumatic screw driver to remove
the hinge from the case.
-5-
5
3
4
2
1
ADJUSTMENT
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 result 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
1. COMPRESSOR
Optional BN
C
BL
t
S
M
P.T.CSTARTER Compressor
C
GN/YL
Figure 19
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 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.
If OLP 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 properly fixed PTC.
-6-
3. OLP (OVER LOAD PROTECTOR)
CONTACTING
POINT
1) Definition of OLP
(1) OLP (OVER LOAD PROTECTOR) is attached to the
Hermetic Compressor and protects the Motor by
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)
COVER
BIMETAL
CONTACTING
POINT
HEATER
TERMINALS
BIMETAL
ADJUST
SCREW
HEATER
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
THERMOSTAT
L
CH
RD
BK
BN
BK
BL
BL
RD:RED
C
BL
BL
GN/YL
OVERLOAD
PROTECTOR
GN/YL
Optional BN
BL
BN:BROWN BL:BLUE
RD
Compressor
pilot lamp
Power pilot lamp
POWER SUPER CORD
BN
Fan
GN/YL
BK:BLACK
t
S
C
M
P.T.CSTARTER Compressor
GN/YL:GREEN&YELLOW
THE PLUG TYPE ON CIRCUIT DIAGRAM IS SUBJECT TO
CHANGE IN DIFFRENT LOCALITIES.
-7-
GN/YL
Figure 20
TROUBLESHOOTING (Mechanical Part)
1. COMPRESSOR AND ELECTRIC COMPONENTS
1
Power
Source.
Remove the Relay Assy
from the Compressor
and measure the voltage
between Terminal C of
Compressor and
Terminals M or S of
Relay Assy
YES
(Rating Voltage
±10%)
2
No Voltage.
5
Applied voltage isn't
in the range of Rating
Voltage ±10%)
2
3
Check the
resistance of
Motor
Compressor.
Check the resistance
among M-C, S-C and
M-S in Motor
Compressor.
Check the
resistance of
PTC-Starter.
Check the resistance of
two terminals in PTCStarter.
Advise the customer
to use a regular
Trans.
5
YES
3
NO Replace Compressor.
3
YES
Check OLP.
Replace
Relay Assy
NO
5
Check
starting state.
Check if applying
a regular OLP.
OLP works within
30 sec. in forcible
OLP operation by
turning instant power
on and off.
Measure minimum
starting voltage after 5
min. for balancing cycle
pressure and cooling the
PTC.
Components start in
the voltage of Rating
Voltage ±10% below
YES
NO
YES
NO
-8-
5
4
YES
4
4
5
5
Replace
Relay Assy
O.K.
1
2. RELAY ASSY (PTC AND OLP)
Check another
electric
components.
Observation value is
220V/50Hz : 22Ω±30%
115V/60Hz : 6.8Ω±30%
240V/50Hz : 33Ω±30%
127, 220V/60Hz :
22Ω±30%
Separate the Relay Assy
from Compressor and
measure the resistance
between M and S with a
Tester or Whistone Bridge.
(Figure 21)
Replace
Relay Assy.
The resistance value is 0
or serveral hundreds Ω.
The value is ∞.
Separate the Relay Assy
from the Compressor and
check the resistance value
between two terminals of
OLP with a Tester.
YES
Check another
electric components.
NO
Replace Relay Assy.
T
L
C
M
N
2
Normal operation of
Compressor is
impossible or poor.
C
S
M
Figure 21
S
Figure 22
-9-
3
2
3. ANOTHER ELECTRIC COMPONENTS
Cooling is impossible
Compressor
doesn't run.
Running state of
Compressor is poor.
Check if current flows to
the following
components.
Cause.
a. Thermistor
Poor contacting.
b. Starting devices
Shorted or broken.
c. OLP
Poor contacting
or shorted.
d. Compressor coil
Coil shorted.
e. Circuit Parts
Poor contacting
or shorted.
Replace
each component.
Check a starting
voltage.
Low voltage.
Raise the voltage.
Check if current flows
to starting devices.
Poor contacting
and broken.
Replace
each component.
Check current flowing
in sub-coil of
Compressor.
Shorted.
Check capacity of OLP.
Lack of capacity.
The items described
above are normal.
Coil of motor
Compressor.
Check current flowing
in SWITCH, DOOR.
Poor contacting.
Check current flowing in the
MOTOR[MECH], FAN.
Coil is shorted.
Replace
the compressor.
Cooling ability is poor
Fan motor
doesn't run.
Much frost are sticked
to the EVAPORATOR.
Replace
each component.
Check current flowing
of the following
components.
• THERMISTOR
• FUSE, MELTING
Shorted.
Check current flowing
of the following
components.
• HEATER, SHEATH
Replace
each component.
Replace
the Heater, Sheath
-10 -
TROUBLE SHOOTING
Fault phenomenon
White indicator
Possible cause for faults
Inspection scope
No input
Poor contact between the plug
lamp not
voltage
and the socket
socket are loose
operating
existing
Poor contact with the white
Inspect whether the connector
Input voltage
existing
Pink indicator
lamp not
opening
Inspect whether the plug and the
Removal
Repair or replace the socket
Notes:
Call an electrician
for repair
Insert the connector assembly
indicator lamp
assembly is loose
tightly
White indicator lamp damaged
Remove the white indicator lamp
Replace
Poor contact between the pink
Inspect whether the connector
Insert the connector assembly
Call professional
indicator lamp and the plug
assembly is loose
tightly
for repair
operating
foot
pink indicator lamp damaged
Compressor set
No put the temperature
not opening
controller to operating state
Remove the pink indicator lamp
Inspect the temperature controller
Replace
Put to the operating state position
as per consideration for use
position
Poor contact with the
Inspect whether the connector
temperature controller
assembly is damaged
Temperature controller
Inspect whether open circuit
damaged
Insert the connector assembly
tightly
Replace the temperature controller
exists in two connector
assemblies
machine set
Over-temperat
Too mush frosting on
operating
ure in the case
evaporator
continuously
Inspect whether thickness is more
Over-high frequency of
Reduce the frequency of opening
opening the door
Too mush articles in the case
Remove the frost timely
than 2mm
the door as much as possible
Inspect whether it is possible to
Take some food out
impact the circulation of cool air.
Refrigerating fluid leaking
Temperature in
Over-high ambient
the case
temperature and too low
reached
temperature of the temperature
Repair in a maintenance point
Inspect whether the knob is put
on Positions
“2-4” or forced
Adjust the knob to Positions
“2-4”
cooling
controller
Temperature controller fault
Replace the temperature controller
Call professional
for repair
Excessive noise,
Case no keep flat
Inspect whether four castor
wheels touch ground
red and green
indicator lamps
Retaining screws of the compressor loosening
Inspect whether the screws are
operating, and
compressor not
operating
Cushion timely
Screw the screws down
screwed down.
Pipelines contacting
Separate the pipeline
Starting relay and thermal protection
Inspect whether the connector
connector assembly loosening
assembly is damaged
Compressor damaged
Voltage less than 187V
Insert the connector assembly
Call professional
for repair
tightly
Repair or replace the compressor
Inspect supply voltage
Connect a voltage stabilizer over
1000V
If the supply cords are damaged, in order to avoid danger, replacement of the supply cords must be carried out by the manufacturer or its maintenance
department or similar full-time staff, and it is not allowed to replace without authorization.
Note: the following phenomenon is not the fault phenomenon
1. Slight gurgle exists in the temperature-changeable freezing refrigerator occasionally;
2 The compressor and the condenser emit heat, even scald hands;
3 It is possible to generate water bubbles outside the refrigerating cabinet when the ambient temperature is higher.
4 The heat of 50 Celsius degree exists outside the temperature outside.
-11-
EXPLODED VIEW
201B
201A
200A
216A
216B
205A
205B
200B
303A
306D
314A
315A
300A
207C
205A
308A
207A
300B
207B
311C
310A
309A
310B
307A
306B
310B
208B
207D
303D
212A
310B
208B
315B
310B
213C
213A
301B
213B
214A
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