WallMountedS24S5 Chassis Inverter ServiceManual
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LG
LG Room Air Conditioner SERVICE MANUAL MODELS: AS-W2465DH0
CAUTION • BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. • ONLY FOR AUTHORIZED SERVICE PERSONNEL.
Air Conditioner Service Manual
TABLE OF CONTENTS LG Model Name.................................................................................................................................3 Safety Precautions ...........................................................................................................................5 Dimensions .....................................................................................................................................10 Installation.......................................................................................................................................12 Flaring work and connection of piping.........................................................................................14 Connecting the cable between indoor unit and outdoor unit.....................................................19 Checking the drainage and forming the pipings .........................................................................21 Air Purging ......................................................................................................................................22 Test Running ...................................................................................................................................24 Functions.........................................................................................................................................25 Operation ........................................................................................................................................28 Disassembly....................................................................................................................................38 Troubleshooting Guide ..................................................................................................................41 and wiring diagram Schematic Diagram ........................................................................................................................63
Product Specifications ..................................................................................................................67 Exploded View ...............................................................................................................................68 Replacement Parts List ..................................................................................................................70
2 Room Air Conditioner
LG Model Name
LG Model Name 2003 1 Code
2
-
3
Type
4
5
6
Code of Model
7
8
9
10
Meaning
1
Producing Center, Refrigerant
A~Z
L: Chang-won R22 A: Chang-won R410A C: Chang-won R407C T: China K: Turkey R22 E: Turkey R410A H: Thailand
2
Product Type
A~Z
S: Split Type Air Conditioner
3
Cooling/Heating/Inverter
A~Z
C: Cooling only H: Heat pump X: C/O + E/Heater Z: H/P + E/Heater
4, 5
Capacity
0~9
Cooling/Heating Capacity Ex. "09" → 9,000 Btu/h
6
Electric Range
1~9 A~Z
1: 115V/60Hz, 2: 220V/60Hz 3: 208-230V/60Hz 5: 200-220V/50Hz 6: 220-240V/50Hz 7: 110V, 50/60Hz 8: 380-415V/50Hz 9: 380-415V/60Hz
7
Chassis
A~Z
Name of Chassis of Unit Ex. LSP → SP Chassis
8
Look
A~Z
9
Function
A~Z
10
Serial No.
0~9
Look, Color (Artcool Model) Basic Basic+4Way Plasma Filter Plasma Filter+4 Way Tele+LCD Tele+LCD+Neo plasma+4Way Neo Plasma F+(A/changeove)+A/clean+Low A Neo Plasma F+(A/changeove)+A/clean+4way+Low A Tele+LED+4way Internet Plasma F+4Way+Oxy generator Neo Plasma F+(A/changeove)+A/clean Neo Plasma F+(A/changeove)+A/clean+4way Neo Plasma F+(A/changeove)+A/clean+PTC Neo Plasma F+(A/changeove)+Autoclean+4way+PTC Neo Plasma F+(A/changeove)+A/clean+4way+Low A+PTC Negative ION+A/Clean (Neo)Plasma+Negative ION+A/Clean 4way+(Neo)Plasma F+Negative ION+Healthy dehumidification+A/Clean Neo Plasma F+4Way+(A/changeove)+A/clean+ LG Model Development Serial No. * ARTCOOL COLOR R Mirror W White B Blue D Wood M Metal C Cherry
N: India Z: Brazil D: Indonesia M: Mexico V: Vietnam S: Out Sourcing
V: AC Inverter C/O N: AC Inverter H/P Q: DC Inverter C/O W: DC Inverter H/P
A: 220V, 50Hz, 3Phase B: 208~230V, 60Hz, 3Phase C: 575V, 50Hz, 3Phase D: 440~460, 60Hz, 3Phase E: 265V, 60Hz F: 200V, 50/60Hz
N A S Q K
A B C D E F G H I J K L M N P Q R S T U
Walnut Gogh Sisley Quran Mecca
Service Manual 3
LG Model Name
2004~ 1 Code
2
-
3
Type
4
5
6
7
Code of Model
8
9
10
Meaning
1
Producing Center, Refrigerant
A~Z
L A C T K E H
Chang_won R22 Chang_won R410A Chang_won R407C China Turkey R22 Turkey R410A Thailand
2
Product Type
A~Z
S: Split Type Air Conditioner
3
Cooling/Heating/Inverter
A~Z
C: Cooling only H: Heat pump X: C/O + E/Heater Z: H/P + E/Heater
4, 5
Capacity
0~9
Cooling/Heating Capacity Ex. "09" → 9,000 Btu/h
6
Electric Range
1~9 A~Z
1: 115V/60Hz, 2: 220V/60Hz 3: 208-230V/60Hz 5: 200-220V/50Hz 6: 220-240V/50Hz 7: 110V, 50/60Hz 8: 380-415V/50Hz 9: 380-415V/60Hz
7
Chassis
A~Z
8
Look
A~Z
Name of Chassis of Unit Ex. LSP → SP Chassis Look, Color (Artcool Model)
9
Function
A~Z
10
Serial No.
0~9
India Brazil Indonesia Mexico Vietnam Out sourcing
V: AC Inverter C/O N: AC Inverter H/P Q: DC Inverter C/O W: DC Inverter H/P
A: 220V, 50Hz, 3Phase B: 208~230V, 60Hz, 3Phase C: 575V, 50Hz, 3Phase D: 440~460, 60Hz, 3Phase E: 265V, 60Hz F: 200V, 50/60Hz CHASSIS S4/S5 S6 SQ SR ST
Look D K L G M N D P
Division Panel Type(Deluxe) Fighting 'Look' (LG1) (LG2)-SEMI PANEL OEM1 OEM2 Panel Type(Deluxe) LG3
Basic Basic+4Way Plasma Filter Plasma Filter+4 Way Tele+LCD Tele+LCD+Neo plasma+4Way NBF F+(A/changeove)+A/clean+Low A NBF F+(A/changeove)+A/clean+4way+Low A Tele+LED+4way Internet Plasma F+4Way+Oxy generator NBF F+(A/changeove)+A/clean NBF F+(A/changeove)+A/clean+4way NBF F+(A/changeove)+A/clean+PTC NBF F+(A/changeove)+Autoclean+4way+PTC NBF F+(A/changeove)+A/clean+4way+Low A+PTC (Neo)Plasma+ION+A/Clean 4way+(Neo)Plasma F+Negative ION+Healthy dehumidification+A/Clean Neo Plasma F+4Way+(A/changeove)+A/clean+Oxy generator 4way+(Neo)Plasma F+Negative ION+Healthy dehumidification+A/Clean+Oxy generator Dry contact Wire remocon
LG Model Development Serial No. * ARTCOOL COLOR R Mirror W White B Blue D Wood M Metal C Cherry
4 Room Air Conditioner
N Z D X V S
A B C D E F G H I J K L M N P Q S T U V W 8
Safety Precautions
Safety Precautions To prevent injury to the user or other people and property damage, the following instructions must be followed. ■ Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications. This symbol indicates the possibility of death or serious injury. This symbol indicates the possibility of injury or damage to properties only. ■ Meanings of symbols used in this manual are as shown below.
Be sure not to do. Be sure to follow the instruction.
■ Installation Do not use damaged power cords, plugs, or a loose socket. • There is risk of fire of electric shock.
Install the panel and the cover of control box securely. • There is risk of fire of electric shock.
Always use the power plug and socket with the ground terminal. • There is risk of electric shock.
Do not modify or extend the power cord.
• No grounding may cause electric shock.
Service Manual 5
Safety Precautions For re-installation of the installed product, always contact a dealer or an authorized service center. • 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.
Do not install the product on a defective installation stand. • It may cause injury, accident, or damage to the product.
6 Room Air Conditioner
Do not install, remove, or re-install the unit by yourself. • There is risk of fire, electric shock, explosion, or injury.
For installation, always contact the dealer or an Authorized service center • There is risk of fire, electric shock, explosion, or injury.
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.
Safety Precautions
■ Operation Do not turn the air-conditioner ON or OFF by plugging or unplugging the power plug. • There is risk of fire or electrical shock.
Grasp the plug to remove the cord from the outlet. Do not touch it with wet hands. • There is risk of fire or electrical shock.
Do not allow water to run into electrical parts.
Use a dedicated outlet for this appliance.
• 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.
Do not store or use flammable gas or combustibles near the air conditioner.
• There is risk of fire, failure of the product, or electric • There is risk of fire or failure of product. shock.
x Wa Thinner
Service Manual 7
Safety Precautions Unplug the unit if strange sounds, odors, or smoke comes from it. • There is risk of electric shock or fire.
Be cautious that water could not enter the product. • There is risk of fire, electric shock, or product damage.
■ Installation Always check for gas (refrigerant) leakage after installation or repair of product. • Low refrigerant levels may cause failure of product.
Keep level even when installing the product. • To avoid vibration or water leakage.
90˚
8 Room Air Conditioner
Install the drain hose to ensure that water is drained away properly. • A bad connection may cause water leakage.
Use two or more people to lift and transport the air conditioner. • Avoid personal injury.
Safety Precautions
■ Operation Use a soft cloth to clean. Do not use harsh detergents, solvents, etc.
Do not touch the metal parts of the product when removing the air filter. They are very sharp!
• There is risk of fire, electric shock, or damage to the • There is risk of personal injury. plastic parts of the product.
x Wa Do not step on or put anyting on the product. (outdoor units)
• There is risk of personal injury and failure of product.
Do not insert hands or other objects through the air inlet or outlet while the air conditioner is plugged in. • There are sharp and moving parts that could cause personal injury.
Service Manual 9
Dimensions
Dimensions Symbols Used in this Manual This symbol alerts you to the risk of electric shock. This symbol alerts you to hazards that could cause harm to the air conditioner.
NOTICE This symbol indicates special notes.
Indoor Unit H
D
W
Installation plate
Model 24k Btu Series Dimension W
mm
1090
H
mm
300
D
mm
178
10 Room Air Conditioner
Dimensions
Outdoor Unit
L1
L11 L10
H
L4
L3
D
L2
W
Gas side
L5
Liquid side L7
L6 MODEL
DIM
L8
L9
24k Btu Series
W
mm
870
H
mm
800
D
mm
320
L1
mm
370
L2
mm
340
L3
mm
25
L4
mm
775
L5
mm
25
L6
mm
546
L7
mm
162
L8
mm
162
L9
mm
54
L10
mm
79
L11
mm
76.4
Service Manual 11
Installation
Installation Selection of the Best Location Indoor unit
Rooftop Installations:
• Do not have any heat or steam near the unit. • Select a place where there are no obstacles in front of the unit. • Make sure that condensation drainage can be conveniently routed away. Do not install near a doorway. • Ensure that the space around the left and right of the unit is more than "A". The unit should be installed as high on the wall as possible, allowing a minimum of "B" from ceiling. • Use a stud finder to locate studs to prevent unnecessary damage to the wall. More than
• If the outdoor unit is installed on a roof structure, be sure to level the unit. Ensure the roof structure and anchoring method are adequate for the unit location. • Consult local codes regarding rooftop mounting.
5cm
Piping Length and Elevation Max. Additional Standard Max. Length Elevation Length Refrigerant A (m) (g/m) (m) B (m)
Pipe Size
Capacity (Btu/h)
GAS
LIQUID
24k
5/8"(Ø15.88)
3/8"(Ø9.52)
4 or 7.5
15
30
30
More than 10cm Indoor unit
More than 5cm More than 2.3m
Outdoor unit
A B
A Indoor unit
Outdoor unit
B
Install the indoor unit on the wall where the height from the floors more than 2.3 meters. Grade 5K~28K 30K~38K
Outdoor unit
Clearance(cm) A 10 30
B 5 12
Oil trap
A
Indoor unit
Outdoor unit
B
• If an awning is built over the unit to prevent direct sunlight or rain exposure, make sure that heat radiation from the condenser is not restricted. • Ensure that the space around the back and sides is more than 10cm. The front of the unit should have more than 70cm of space. • Do not place animals and plants in the path of the warm air. • Take the air conditioner weight into account and select a place where noise and vibration are minimum. • Select a place so that the warm air and noise from the air conditioner do not disturb neighbors. More than 60cm More than 10cm
More than 70cm
12 Room Air Conditioner
More than 10cm
More than 60cm
If case more than 5m
• Capacity is based on standard length and maximum allowance length is on the basis of reliability. • Oil trap should be installed every 5~7 meters.
I
Installation
The wall you select should be strong and solid enough to prevent vibration 1. Mount the installation plate on the wall with four type A screws. If mounting the unit on a concrete wall, use anchor bolts. • Mount the installation plate horizontally by aligning the centerline using a level.
Drill a Hole in the Wall • Drill the piping hole with a ø70mm hole core drill. Drill the piping hole at either the right or the left with the hole slightly slanted to the outdoor side. WALL Indoor
Outdoor
5-7mm
Installation Plate
Chassis Hook Type "A" screw
2. Measure the wall and mark the centerline. It is also important to use caution concerning the location of the installation plate-routing of the wiring to power outlets is through the walls typically. Drilling the hole through the wall for piping connections must be done safely.
(3/16"~5/16")
How to Fix Installation Plate
• Open the Front Grille. • Pass Telephone Control Cord Wire through the hole which the power cord goes through. • Connect Telephone Control Cord Wire to the phone jack of telephone PCB of Control Box. • Fix Telephone Control Cord Wire inside Control box so as not to disconnect. • Close the Front Grille.
Drain hose junction • Remove the rubber stopple in the desired drain direction. Installation plate D
B
Ø70mm
A
C Left rear piping
CHASSIS (Grade) 7k, 9k, 12k, 14k 18k, 24k
Ø70mm
Right rear piping
• Insert drain hose into the handle of drain pan, and join drain hose and connecting hose according to the figure by.
Distance (mm) A 75 105
B 65 65
C 105 260
D 65 65
Adhesive Only the desired direction Connecting part Drain hose
Service Manual 13
Flaring work and connection of piping
Flaring work and connection of piping Flaring work
• Carry out flaring work using flaring tool as shown below.
Flaring work Main cause for refrigerant leakage is due to defect in the flaring work. Carry out correct flaring work using the following procedure. Cut the pipes and the cable. • Use the piping kit accessory or pipes purchased locally. • Measure the distance between the indoor and the outdoor unit. • Cut the pipes a little longer than the measured distance. • Cut the cable 1.5m longer than the pipe length.
Outside diameter mm inch
A mm
Ø9.52
3/8
0~0.5
Ø15.88
5/8
0~1.0
Check • Compare the flared work with figure below.
Copper pipe
90°
Slanted Uneven Rough
• If flare is noted to be defective, cut off the flared section and re-flare it. Smooth all round Inside is shiny without scratches
Burr removal
= Improper flaring =
• Completely remove all burrs from the cut cross section of pipe/tube. • Put the end of the copper tube/pipe in a downward direction as you remove burrs in order to avoid dropping burrs into the tubing.
Even length all round
Inclined Surface Cracked Uneven damaged thickness
Connection of piping -- Indoor
Pipe Reamer
• Preparing the indoor unit's piping and drain hose for installation through the wall.
Point down
• Remove the plastic tubing retainer(see illustration below) and pull the tubing and drain hose away from chassis.
Putting nut on • Remove flare nuts attached to indoor and outdoor unit, then put them on pipe/tube having completed burr removal. (not possible to put them on after flaring work)
• Replace the plastic tubing holder in the original position.(Optional)
Flare nut Drain hose
Copper tube
Flaring work • Firmly hold copper pipe in a die in the dimension shown in the table above. "A"
Bar
Handle Bar Yoke Cone
Copper pipe Clamp handle
Red arrow mark
14 Room Air Conditioner
When install, make sure that the remaining parts must be removed clearly so as not to damage the piping and drain hose, especially power cord and connecting cable.
Flaring work and connection of piping Connecting the pipings to the indoor unit and drain hose to drain pipe.
For right rear piping Route the indoor tubing and the drain hose in the direction of rear right.
• Align the center of the pipes and sufficiently tighten the flare nut by hand.
Drain hose
Indoor unit tubing
Flare nut
Pipes
• Tighten the flare nut with a wrench. Insert the connecting cable into the indoor unit from the outdoor unit through the piping hole.
Open-end wrench (fixed) Flare nut
• Do not connect the cable to the indoor unit. • Make a small loop with the cable for easy connection later.
Wrench
Connection pipe
Indoor unit tubing
Tape the tubing, drain hose, and the connecting cable. Be sure that the drain hose is located at the lowest side of the bundle. Locating at the upper side can cause drain pan to overflow inside the unit.
Outside diameter mm inch Ø9.52 3/8 Ø15.88 5/8
Torque kg.m 4.2 6.6
• When extending the drain hose at the indoor unit, install the drain pipe. Tape Connecting pipe
Drain pipe
Drain hose
Connecting cable
NOTE: If the drain hose is routed inside the room, insulate the hose with an insulation material* so that dripping from "sweating"(condensation) will not damage furniture or floors. *Foamed polyethylene or equivalent is recommended.
Indoor unit installation
Indoor unit drain hose Adhesive
•Overlap the connection pipe insulation material and the indoor unit pipe insulation material. Bind them together with vinyl tape so that there is no gap.
• Hook the indoor unit onto the upper portion of the installation plate.(Engage the two hooks of the rear top of the indoor unit with the upper edge of the installation plate.) Ensure that the hooks are properly seated on the installation plate by moving it left and right.
Connecting cable
Vinyl tape(narrow)
Wrap the insulation material around the connecting portion.
Plastic bands Insulation material
• Wrap the area which accommodates the rear piping housing section with vinyl tape. Indoor unit pipe
Connection pipe
Drain hose
Press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots(clicking sound).
Vinyl tape Wrap with vinyl tape (wide) Connecting cable
Pipe Vinyl tape(narrow)
Service Manual 15
Flaring work and connection of piping • Bundle the piping and drain hose together by wrapping them with vinyl tape for enough to cover where they fit into the rear piping housing section. Wrap with vinyl tape
Connecting the pipings to the indoor unit and the drain hose to drain pipe. • Align the center of the pipes and sufficiently tighten the flare nut by hand.
Pipe
Vinyl tape(wide)
Indoor unit tubing
Drain hose
For left rear piping
Flare nut
Pipes
• Tighten the flare nut with a wrench.
Route the indoor tubing and the drain hose to the required piping hole position.
Open-end wrench (fixed) Flare nut Wrench
Connection pipe
Indoor unit tubing
Insert the piping, drain hose, and the connecting cable into the piping hole.
Outside diameter mm inch Ø9.52 3/8 Ø15.88 5/8
Torque kg.m 4.2 6.6
Connecting cable Drain pipe
• When extending the drain hose at the indoor unit, install the drain pipe.
Insert the connecting cable into the indoor unit. • Don't connect the cable to the indoor unit.
Drain hose
• Make a small loop with the cable for easy connection later.
Tape the drain hose and the connecting cable. Indoor unit drain hose
• Connecting cable Adhesive
Vinyl tape (narrow)
Wrap the insulation material around the connecting portion. • Overlap the connection pipe heat insulation and the indoor unit pipe heat insulation material. Bind them together with vinyl tape so that there is no gap.
Indoor unit installation
Plastic bands Insulation material
• Hang the indoor unit from the hooks at the top of the installation plate. • Insert the spacer etc. between the indoor unit and the installation plate and separate the bottom of the indoor unit from the wall. Indoor unit Spacer Installation plate 8cm
16 Room Air Conditioner
Flaring work and connection of piping • Wrap the area which accommodates the rear piping housing section with vinyl tape. Indoor unit piping
Connection pipe Vinyl tape (wide)
Wrap with vinyl tape
Indoor unit installation • Remove the spacer. • Ensure that the hooks are properly seated on the installation plate by moving it left and right.
Pipe Vinyl tape(narrow)
Connecting cable
Connecting cable
Drain hose
• Bundle the piping and drain hose together by wrapping them with cloth tape over the range within which they fit into the rear piping housing section.
Press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots(clicking sound).
Pipe Drain hose Vinyl tape(narrow)
Installation Information (For left piping) • Good case For left piping. Follow the instruction below.
Wrap with vinyl tape(wide)
• Press on the upper side of clamp. ( )
Reroute the pipings and the drain hose across the back of the chassis. • Unfold the tubing to downward slowly. ( )
Piping for passage through piping hole
Set the pipings and the drain hose to the back of the chassis with the tubing holder. • Hook the edge of tubing holder to tap on chassis and push the bottom of tubing holder to be engaged at the bottom of chassis.
• Bend the tubing to the left side of chassis.
Tubing holder
Service Manual 17
Flaring work and connection of piping
Connection of the pipes-Outdoor • Bad case • Following bending type from right to left could cause problem of pipe damage.
Align the center of the pipings and sufficiently tighten the flare nut by hand.
Finally, tighten the flare nut with torque wrench until the wrench clicks. • When tightening the flare nut with torque wrench, ensure the direction for tightening follows the arrow on the wrench. Outside diameter mm inch Ø9.52 3/8 Ø15.88 5/8
Torque kg.m 4.2 6.6
Outdoor unit Gas side piping (Bigger diameter)
Liquid side piping (Smaller diameter)
Torque wrench
18 Room Air Conditioner
Connecting the cable between indoor unit and outdoor unit
Connecting the cable between indoor unit and outdoor unit Connect the cable to the Indoor unit. Connect the cable to the indoor unit by connecting the wires to the terminals on the control board individually according to the outdoor unit connection. (Ensure that the color of the wires of the outdoor unit and the terminal No. are the same as those of the indoor unit.)
• The above circuit diagram is subject to change without notice. • The earth wire should be longer than the common wires. • When installing, refer to the circuit diagram behind the panel front of the indoor unit. • Connect the wires firmly so that they may not be pulled out easily. • Connect the wires according to color codes, referring to the wiring diagram.
Main power source
If a power plug is not used, provide a circuit breaker between power source and the unit as shown by.
Air Conditioner
Circuit Breaker Use a circuit breaker or time delay fuse.
The power cord connected to the "A" unit should be selected according to the following specifications(Type "B" approved by HAR or SAA). (mm2) Grade NORMAL CROSS -SECTIONAL AREA
24k
Unit(A)
Indoor
Cable Type(B)
H05VV-F
2.5
The power connecting cable connecting the indoor and outdoor unit should be selected according to the following specifications (Type "B" approved by HAR or SAA). (mm2) Grade NORMAL CROSS -SECTIONAL AREA
24k
Cable Type(B)
H07RN-F
2.5
Service Manual 19
Connecting the cable between indoor unit and outdoor unit
Connect the cable to the outdoor unit
Outdoor Unit
Remove the control cover from the unit by loosening the screw.
Terminal block
Connect the wires to the terminals on the control board individually.
Over 5mm
Connecting cable
Secure the cable onto the control board with the cord clamp. Refix the control cover to the original position with the screw.
Connecting cable
Cover control
Use a recognized circuit breaker "A" between the power source and the unit. A disconnecting device to adequately disconnect all supply lines must be fitted. Circuit Breaker (A)
Grade 24k 30
After the confirmation of the above conditions, prepare the wiring as follows: 1) Never fail to have an individual power circuit specifically for the air conditioner. As for the method of wiring, be guided by the circuit diagram posted on the inside of control cover. 2) The screw which fasten the wiring in the casing of electrical fittings are liable to come loose from vibrations to which the unit is subjected during the course of transportation. Check them and make sure that they are all tightly fastened. (If they are loose, it could cause burn-out of the wires.) 3) Specification of power source. 4) Confirm that electrical capacity is sufficient. 5) See to that the starting voltage is maintained at more than 90 percent of the rated voltage marked on the name plate. 6) Confirm that the cable thickness is as specified in the power source specification. (Particularly note the relation between cable length and thickness. (Refer to page 21)) 7) Always install an earth leakage circuit breaker in a wet or moist area. 8) The following would be caused by voltage drop. • Vibration of a magnetic switch, which will damage the contact point, fuse breaking, disturbance of the normal function of the overload. 9) The means for disconnection from a power supply shall be incorporated in the fixed wiring and have an air gap contact separation of at least 3mm in each active(phase) conductors.
20 Room Air Conditioner S24AW Service Manual A20462R.pdf
Checking the drainage and forming the pipings
Checking the drainage and forming the pipings Checking the drainage
Form the piping
To remove the front panel from the indoor unit. • Set the air direction louvers up-and-down to the position(horizontally) by hand.
Form the piping by wrapping the connecting portion of the indoor unit with insulation material and secure it with two kinds of vinyl tapes.
• Remove the securing screws that retain the front panel. Pull the lower left and right sides of the grille toward you and lift it off.
• If you want to connect an additional drain hose, the end of the drain outlet should be routed above the ground. Secure the drain hose appropriately.
In cases where the outdoor unit is installed below the indoor unit perform the following. • Tape the piping, drain hose and connecting cable from down to up. Pull the right and the left side.
• Secure the tapped piping along the exterior wall using saddle or equivalent. Seal small openings around pipings with a gum type sealer.
To check the drainage. • Pour a glass of water on the evaporator. • Ensure the water flows through the drain hose of the indoor unit without any leakage and goes out the drain exit.
Taping Drain hose
Pipings Connecting cable
Trap is required to prevent water from entering into electrical parts.
In cases where the Outdoor unit is installed above the Indoor unit perform the following. • Tape the piping and connecting cable from down to up.
Drain piping • The drain hose should point downward for easy drain flow.
• Secure the taped piping along the exterior wall. Form a trap to prevent water entering the room. • Fix the piping onto the wall by saddle or equivalent.
Downward slope
Seal a small opening around the pipings with gum type sealer. Trap
• Do not make drain piping. Accumulated drain water Air
Do not raise
Water leakage
Water leakage
Waving
Tip of drain hose dipped in water Water leakage
Less than 50mm gap
Trap
Ditch
Service Manual 21
Air purging
Air Purging Air purging Air and moisture remaining in the refrigerant system have undesirable effects as indicated below. • Pressure in the system rises. • Operating current rises. • Cooling(or heating) efficiency drops.
• Do a leak test of all joints of the tubing(both indoor and outdoor) and both gas and liquid side service valves. Bubbles indicate a leak. Be sure to wipe off the soap with a clean cloth. • After the system is found to be free of leaks, relieve the nitrogen pressure by loosening the charge hose connector at the nitrogen cylinder. When the system pressure is reduced to normal, disconnect the hose from the cylinder.
• Moisture in the refrigerant circuit may freeze and block capillary tubing. • Water may lead to corrosion of parts in the refrigeration system.
Indoor unit
Therefore, the indoor unit and tubing between the indoor and outdoor unit must be leak tested and evacuated to remove any noncondensables and moisture from the system.
Air purging with vacuum pump Preparation • Check that each tube(both liquid and gas side tubes) between the indoor and outdoor units have been properly connected and all wiring for the test run has been completed. Remove the service valve caps from both the gas and the liquid side on the outdoor unit. Note that both the liquid and the gas side service valves on the outdoor unit are kept closed at this stage.
Outdoor unit
Leak test • Connect the manifold valve(with pressure gauges) and dry nitrogen gas cylinder to this service port with charge hoses.
Manifold valve Pressure gauge
Lo
Hi
Be sure to use a manifold valve for air purging. If it is not available, use a stop valve for this purpose. The "Hi" knob of the manifold valve must always be kept close. • Pressurize the system to no more than 150 P.S.I.G. with dry nitrogen gas and close the cylinder valve when the gauge reading reached 150 P.S.I.G. Next, test for leaks with liquid soap.
To avoid nitrogen entering the refrigerant system in a liquid state, the top of the cylinder must be higher than its bottom when you pressurize the system. Usually, the cylinder is used in a vertical standing position.
22 Room Air Conditioner
Charge hose
Nitrogen gas cylinder(in vertical standing position)
Air purging Soap water method (1) Remove the caps from the 2-way and 3-way valves.
Gas side
(2) Remove the service-port cap from the 3-way valve. (3) To open the 2-way valve turn the valve stem counterclockwise approximately 90°, wait for about 2~3 sec, and close it. (4) Apply a soap water or a liquid neutral detergent on the indoor unit connection or outdoor unit connections by a soft brush to check for leakage of the connecting points of the piping.
Liquid side 3-way valve (Close) 2-way valve (Open)
(5) If bubbles come out, the pipes have leakage.
Cap
Evacuation
Hexagonal wrench
• Connect the charge hose end described in the preceding steps to the vacuum pump to evacuate the tubing and indoor unit. Confirm the "Lo" knob of the manifold valve is open. Then, run the vacuum pump. The operation time for evacuation varies with tubing length and capacity of the pump. The following table shows the time required for evacuation.
Indoor unit
Required time for evacuation when 30 gal/h vacuum pump is used If tubing length is less than 10m (33 ft) if tubing length is longer than 10m (33 ft) 10 min. or more
Outdoor unit
15 min. or more
• When the desired vacuum is reached, close the "Lo" knob of the manifold valve and stop the vacuum pump.
Finishing the job • With a service valve wrench, turn the valve stem of liquid side valve counter-clockwise to fully open the valve. • Turn the valve stem of gas side valve counter-clockwise to fully open the valve. • Loosen the charge hose connected to the gas side service port slightly to release the pressure, then remove the hose. • Replace the flare nut and its bonnet on the gas side service port and fasten the flare nut securely with an adjustable wrench. This process is very important to prevent leakage from the system.
Manifold valve Pressure gauge
Lo
Hi
Open
Close
• Replace the valve caps at both gas and liquid side service valves and fasten them tight. This completes air purging with a vacuum pump. The air conditioner is now ready to test run. Vacuum pump
Service Manual 23
Test running
Test Running 1. Check that all tubing and wiring have been properly connected. 2. Check that the gas and liquid side service valves are fully open.
NOTE: If the actual pressure is higher than shown, the system is most likely over-charged, and charge should be removed. If the actual pressure are lower than shown, the system is most likely undercharged, and charge should be added. The air conditioner is now ready for use.
Settlement of outdoor unit • Anchor the outdoor unit with a bolt and nut(ø10mm) tightly and horizontally on a concrete or rigid mount. • When installing on the wall, roof or rooftop, anchor the mounting base securely with a nail or wire assuming the influence of wind and earthquake. • In the case when the vibration of the unit is conveyed to the hose, secure the unit with an anti-vibration bushing.
PUMP DOWN This is performed when the unit is to be relocated or the refrigerant circuit is serviced. Pump Down means collecting all refrigerant in the outdoor unit without loss in refrigerant gas. CAUTION: Be sure to perform Pump Down procedure with the unit cooling mode. Pump Down Procedure 1. Connect a low-pressure gauge manifold hose to the charge port on the gas side service valve.
Bolt
2. Open the gas side service valve halfway and purge the air from the manifold hose using the refrigerant gas. 3. Close the liquid side service valve(all the way in). Tubing connection
Evaluation of the performance Operate unit for 15~20 minutes, then check the system refrigerant charge: 1. Measure the pressure of the gas side service valve. 2. Measure the temperature of the intake and discharge of air. 3. Ensure the difference between the intake temperature and the discharge is more than 8°C(46°F) (Cooling) or (Heating). Intake temperature Discharge air
4. Turn on the unit's operating switch and start the cooling operation. 5. When the low-pressure gauge reading becomes 1 to 0.5kg/cm2 G(14.2 to 7.1 P.S.I.G.), fully close the gas side valve stem and then quickly turn off the unit. At that time, Pump Down has been completed and all refrigerant gas will have been collected in the outdoor unit. Power-Failure Compensation Function User Selection ON/OFF 1) Operation Sequence Press the forced switch until BUZZER sounds 2 times (beep~beep~). Release the forced switch if BUZZER sounds. Check the function selection ON/OFF with the operation LED. 2) Checking function-selection ON/OFF
Discharge temperature
4. For reference; the gas side pressure of optimum condition is as below.(Cooling) Refrigerant
Outside ambient TEMP.
R-410A
35°C (95°F)
- Function-Selection ON: One time blinking of operation LED would repeat 4 times. - Function-Selection OFF: Two times blinking of operation LED would repeat 4 times.
The pressure of the gas side service valve. 8.5~9.5kg/cm2G(120~135 P.S.I.G.)
Power button
24 Room Air Conditioner
Functions
Functions Indoor Unit Cooling Mode Operation Healty dehumidification Mode Operation Heating Mode Operation Jet Cool Mode Operation Jet Heat Mode Operation Energy Saving Cooling Mode Operation Operation ON/OFF by Remote controller Sensing the Room Temperature • Room temperature sensor. (Thermistor) • Pipe temperature sensor. (Thermistor) Room temperature control • Maintain the room temperature in accordance with the Setting Temp. Starting the Current Control • Indoor fan is delayed for 5 sec at the starting. Time Delay Safety Control • Restarting is for approx. 2 minutes. Indoor Fan Speed Control • Super High, High, Med, Low Operation indication Lamps (LED) --- Lights up in operation --- Lights up in Sleep Mode (Optional) --- Lights up in Timer Mode --- Lights up in Preheat Mode (for Heating Model) --- Lights up in Plasma Air Clean Mode --- Lights up in during Energy-Saving Cooling Mode Operation (Optional)
Service Manual 25
Functions Sleep Mode Auto Control • The fan is switched to low(Cooling), low(Heating) speed. • The unit will be stopped after 1, 2, 3, 4, 5, 6, 7 hours. Natural Air Control by CHAOS Logic • The fan is switched to intermittent or irregular operation • The fan speed is automatically switched from high to low speed. Airflow Direction Control • The louver can be set at the desired position or swing up and down automatically. Auto Changeover Energy-Saving Control(Optional) Horizontal airflow Direction Control(Optional) Auto Clean(Optional) Plasma • The function will be operated while in any operation mode with selecting the function. • The function is to be stopped while it isoperating with selecting the function. Defrost(Deice) Control (Heating) • Both the indoor and outdoor fan stops during defrosting. Hot-start Control (Heating) • The indoor fan stops until the evaporator pipe temperature will be reached at 34°C. Heater (Optional)
26 Room Air Conditioner
Functions Outdoor Unit Power Relay Control • If power is on, it will operate to chage capacitor on controller and power relay will operate after about 2~5sec. Active Power Filter Control(PSC) • The active power filter is designed to correct power factor(cos θ) and to regulate DC link voltage. • It will be operated PFC circuit when the compressor freq. is over 30Hz and wattage is over 450 watt. Comp. Freq. Control • The final operating freq. of comp. is set the lowest freq. that limited outdoor temp., discharge pipe temp., heat-sink temp., target freq., owing to CT. OverheatIng. Protection(Power Module) • When the temp. of power module increases to 85°C, controller decreases Freq. of Comp. Freq. Speed Control(Up/Down Speed) • It will be changed the drive freq. of comp. according to temp. of indoor and outdoor. Total Current Control (Over Current Protection) DC Peak Current Control 4 way Valve Control • It is only operated in the heating operation mode except defrosting operation. Outdoor Fan Motor Control • High speed - Although fan motor speed is middle, it will change high speed in case of below AC193V, over 45°C of outdoor temp., and over fc, fh of comp. Freq. • Low speed - Although fan motor speed is middle, it will change Low speed in case of over AC 270V, over 21°C (Heating Mode) of outdoor temp. below 24°C (Cooling Mode) of outdoor temp. Discharge Pipe Temp. Control Low Ambient Over Heating Protection (Comp.)
Service Manual 27
Operation
Operation Function of Controls • DISPLAY 1) C/O Model Operation Indicator • ON while in appliance operation, OFF while in appliance pause. • Flashing while in disconnection or short in Thermistor. (3 sec off / 0.5 sec on) Timer Indicator • ON while in timer mode (on/off), OFF when timer mode is completed or canceled. Comp. Running Incidator • While in appliance operation, ON while in outdoor unit compressor running, OFF while in compressor off. 2) H/P Model Operation Indicator • ON while in appliance operation, OFF while in appliance pause. • Flashing while in disconnection or short in Thermistor. (3 sec off / 0.5 sec on) Timer Indicator • ON while in timer mode (on/off), OFF when timer mode is completed or canceled. Defrost Indicator • OFF except when hot start during heating mode operation or while in defrost control.
Protection of the evaporator pipe from frosting • If the indoor pipe temperaure is below 0°C in 7 min. after the compressor operates without pause while in cooling cycle operation mode, ➔ compressor, outdoor fan are turned off. • When indoor pipe temp. is 7°C or higher after 2 min pause of compressor ➔ compressor, outdoor fan is turned on according to the condition of the room temperature.
Comp. free 6˚C 3˚C 0˚C
Comp. Step 4 Comp. Step 2 Comp. off
28 Room Air Conditioner
Indoor pipe temp. 7˚C
Operation
Cooling Mode Operation • When the intake air temperature reaches 0.5°C below the setting temp, the compressor and the outdoor fan stop. • When it reaches 0.5°C above the setting temp, they start to operate again. Compressor ON Temp ➲ Setting Temp+0.5°C Compressor OFF Temp ➲ Setting Temp-0.5°C • While in compressor running, operating with the airflow speed set by the remote control. While compressor is off fan operates at low speed regardless of the setting.
Healthy Dehumidification Mode Operation • When the dehumidification operation input by the remote control is received, the intake air temperature is detected and the setting temp is automatically set according to the intake air temperature. 26°C ≤ Intake Air Temp ➲ 25°C 24°C ≤ Intake Intake Air Temp
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