LG 230-208V User Manual

Room

Air Conditioner

SERVICE MANUAL

CAUTION

website http://www.lgservice.com

• BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

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1. PREFACE

1.1 SPECIFICATIONS ..........................................3

1.2 FEATURES AND BENEFITS..........................4

1.3 CONTROL LOCATIONS.................................6

1.4 ADDITIONAL CONTROLS..............................7

DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS....................................9

2.1.1 FRONT GRILLE.....................................9

2.1.2 CONTROL BOX (Half-Disassembly)....10

2.1.3 CONTROL BOX (Full-Disassembly)....10

2.2 AIR HANDLING PARTS................................11

2.2.1 HEATER ASSEMBLY AND CROSS

FLOW FAN...........................................11

2.2.2 FAN......................................................11

2.2.3 SHROUD..............................................12

2.3 ELECTRICAL PARTS...................................12

2.3.1 OUTDOOR MOTOR ............................12

2.3.2 INDOOR MOTOR ................................12

2.3.3 COMPRESSOR...................................12

2.3.4 CAPACITOR........................................12

2.3.5 POWER CORD....................................13

2.3.6 P.C.B....................................................13

2.4 REFRIGERATION CYCLE............................14

2.4.1 CONDENSER......................................14

2.4.2 EVAPORATOR....................................14

2.4.3 CAPILLARY TUBE...............................14

INSTALLATION

3.1 HOW TO INSTALL THE UNIT ......................17

3.2 SUGGESTED TOOL REQUIREMENTS.......18

3.2.1 PREPARATION OF SLEEVE ..............18

3.2.2 PREPARATION OF THE FRONT

GRILLE ................................................18

3.2.3 UNIT INSTALLATION..........................19

3.3 ELECTRICAL REQUIREMENTS..................20

3.3.1

ELECTRICAL DATA (FOR 230V/208 MODEL)........

3.3.2 ELECTRICAL SAFETY

............................

FERFORMANCE DATA

.................................

TROUBLESHOOTING GUIDE

5.1 OUTSIDE DIMENSIONS...............................26

5.2 PIPING SYSTEM ..........................................26

5.3 TROUBLESHOOTING GUIDE......................27

6. SCHEMATIC DIAGRAM.....................32

7. EXPLODED VIEW..................................33

8. REPLACEMENT PARTS LIST.......34

1. PREFACE

This

SERVICE MANUAL provides various service information, including the mechanical and electrical

parts etc. This room air conditioner was manufactured and assembled under a strict quality control system. The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.

1.1 SAFETY PRECAUTIONS

1. When servicing the unit, set the ROTARY SWITCH or POWER SWITCH to OFF(O) and unplug the power cord.

2. Observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or damaged by the short circuit.

3. After servicing the unit, make an insulation resistance test to protect the customer from being exposed to shock hazards.

1.2

INSULATION RESISTANCE TEST

1. Unplug the power cord and connect a jumper between 2 pins (black and white).

2. The grounding conductor (green or green & yellow) is to be open.

3. Measure the resistance value with an ohm meter between the jumpered lead and each exposed metallic part on the equipment at all the positions (except OFF or O) of the ROTARY SWITCH.

4. The value should be over 2MΩ.

CONTENTS

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1.1 SPECIFICATIONS

LP120CEM 11800/11500 1055/1025 11.2/11.2 - - 20

Model Name Cooling(Btu/h) Cooling Watts(W) EER

Electric Heat

(Btu/h)

Electric Heat

Amps(A)

Min Circuit

Protection (Amps)

Cooling / Electric Heater

LP090HEM 9300/9000 800/775 11.6/11.6 8200/8000 3.4/3.4 11900/9900 3.2/3.5 20 LP120HEM 12100/11800 1090/1065 11.1/11.1 10900/10700 3.3/3.3 11900/9900 4.4/4.8 20

Model Name Cooling(Btu/h)

Cooling

Watts(W)

EER

Electric Cycle

Heat (Btu/h)

COP

Electric Heat

(Btu/h)

Electric Heat

Amps(A)

Min Circuit

Protection (Amps)

Cooling / Heat Pump / Electric

LP 12 0 C M 2

12 34 5 6 7 8 Digits 1,2 - LG Packaged Terminal Air Conditioner Digit 6 - Product Type

Digits 3,4 - Unit Cooling Capacity C = Air Conditoner 07 = 7,000 Btu/h H = Heat Pump 09 = 9,000 Btu/h Digit 7- Control Type 12 = 12,000 Btu/h M = Mechanical Control 15 = 15,000 Btu/h Digit 8 - Electric Heating Capacity Digit 5 - Serial No. 2 = 2.0 kW 3 = 3.5 kW 5 = 5.0 kW

1.2 features

Unit Features

The PTAC has many features, some of which are different than those found on conventional PTAC units. The servicer must be familiar with these features in order to

properly service the unit.

• Highly featured Micom controls using IIR (infinite impulse response) IIR function can make Micom controls maximize and keep the comfort conditions to sense the small changes in temperature per second.

• Compressor Restart delay

This feature extends the overall life of compressor by preventing the short-cycling of the air-conditioner. When the compressor restarts, LG PTAC is designed to give a minimum of three minutes to have a time of equalizing the refrigerant pressures for optimizing cycling.

• Fan-Only Setting - High/Low

The unit provides the function of selecting the either High or Low speed for Fan-Only operation.

• Indoor Fan Speed Selections - High/Low

The unit is operated in High-Heat or Low-Heat or High Cool or Low Cool.

• Two Fan motors

The unit has two fan motors to provide the occupants with the quiet environment to enjoy the peaceful life and maximum operating efficiency.

• LED Diagnostics

All units have this feature indicating the problem when the unit is not operating properly with easy -to-read diagnostics. For example, 1 blink every 2 seconds indicates the compressor failure.

• Indoor Filters

The unit uses the two indoor filters easily slide in and out. The filters may be cleaned by washing and brushing without removing the front grille.

• Rotary Compressor

The unit uses the rotary compressor for the quiet, reliable operation and prolong life.

• 2 Position Discharge Grille

The discharge grille can provide air flows upward at an angle of 40 off vertical or 80 15 degree off vertical. An angle is changed by removing the front grille and 4screws that fasten the discharge grille to the front grille to rotate an alternate position of the louvers.

• Indoor Room Freeze Protection

When the unit senses the room temperature falls to 40˚F below, the unit activates the fan motor and either the electric resistance heater or the hydronic heater to prevent pipes or fixtures from freezing. This also overrides front desk control of the unit mounted or wall mounted controls.

• Door Switch/Occupancy Sensor

The unit is capable of accommodating a field installed door switch and occupancy sensor to operate the energy management feature. For additional information, refer to the Unit Operation section.

• Compressor Overload Protection

This feature prevents the damage of the compressor by sensing the indoor tube temperature in heating. If the indoor temperature is over 130˚F, the outdoor fan will be switched off and on below 120˚F.

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• Outdoor Air Temperature Switchover

The unit is designed to control the electric heater interfacing with the outdoor temperature. When the outdoor temperature falls to 20˚F below, it makes the compressor be off and the electric heater be turned on until the outdoor temperature is above 25˚F. This will effectively change the Unit from heat pump mode to total electric resistance heat.

• Temperature limits

The unit is programmed to provide both heating and cooling temperature limits by dip switches on control panel from 50˚F to 90˚F. Temperature limits help to prevent overheating and overcooling for reducing the energy costs.

• Condensate Drain Valve

The unit has the condensate drain valve that prevents water from freezing in basepan.

• Quick Heater Recovery

The unit is designed to operate the electric heater to warm the room to the temperature set point as soon as heat pump cycle is on in heating. This feature has an advantage of reducing the time to reach the set point and improving the temperature increase for better comfort.

• Reverse Cycle Defrosting - (PTHDs only)

The unit will activate the reverse cycle defrost When the outdoor coil temperature has remained at a cold temperature to form the ice on the coil.This ice will reduce airflow though the coil and will also reduce the efficiency of unit. The LG PTHP will employ an active reverse cycle defrost function to melt the ice off the outdoor coil for insuring room comfort conditions and savings from extended operation.

• High Temperature Heat Pump Operation Protection

The compressor will be switched off to prevent damage when the heat pump is operated in high outdoor temperatures.

• Remote Thermostat Control

Each unit is built to be operated from any standard 4 or 5 wire remote-mounted thermostat, if desired. The unit has a built-in low voltage power source which can accommodate a large variety of thermostat choices-manual, auto changeover or programmable. A remote thermostat can also be added to any installed unit.

• Zone Sensor

Occupants enjoy ultimate comfort with consistent climate control. Attach an optional, inexpensive remote Zone Sensor, to exactly match the functions of the PTAC without disabling any features.

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1.3 CONTROL LOCATIONS

• OPERATION

ELECTRIC HEATING MODEL COOLING ONLY MODEL

VENT

OPEN

TEMPERATURE CONTROL

Set the Thermostat control to the desired temperature mark 5 (the mid-point is a good starting position). If the room temperature is not satisfactory after a reasonable time, adjust the control to a cooler or warmer setting, as appropriate.

OPERATION MODE SELECTOR

OFF: Turns air conditioner off. LOW FAN: Low speed fan operation without cooling. HIGH FAN: High speed fan operation without cooling. LOW COOL: Cooling with the low speed fan operation. HIGH COOL: Cooling with the high speed fan operation. LOW HEAT: Heating with the low speed fan operation. HIGH HEAT: Heating with the high speed fan operation.

• VENTILATION

The ventilation lever is located to the lower left side of the unit. The ventilation lever must be in the CLOSE position in order to maintain the best cooling conditions. When fresh air is necessary in the room, set the ventilation lever to the OPEN position. The damper is opened and outdoor air is drawn into the room. This will reduce the cooling or heating efficiency.

When the air conditioner has performed a cooling or heating operation and is turned off or set to the fan position, wait at least 3 minutes before resetting to the cooling operation.

A slight heat odor may come from the unit when first switching to HEAT after the cooling season is over. This odor, caused by fine dust particles on the heater, will disappear quickly. This is harmless.

CAUTION

NOTE

1.4 ADDITIONAL CONTROLS

• REMOVING THE FRONT GRILLE

Additional controls are available after removing the front grille and option cover of control box. To remove the front grille, pull out the bottom of front grille and then lift up. To replace the front grille, place the tabs over the top of the unit and push the bottom of front grille until the clips snap into place.

• ADDITIONAL CONTROLS

The additional controls are located behind the option cover of control box. The standard settings will be in the OFF position. The authorized service man has to check switches and ensure the switches are in the desired position.

• TEMPERATURE LIMITING

Temperature Limiting can save money by limiting the lowest temperature for cooling and the highest temperature for heating. The temperature limiting is controlled by dip switch #1 - #3. This temperature limiting is not available with the Remote Wall Thermostat.

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ONREMOTE

OFF

ON ON ON

Remote/Local Energy Saver Temperature Limit 1 Temperature Limit 2 Temperature Limit 3

LOCALLOCAL

OFF

LOCAL

OFF2OFF3OFF4OFF

LOCALLOCAL

OFF

LOCAL

OFF2OFF3OFF4OFF

Temperature Temperature Temperature

Limit #1 Limit #2 Limit #3

OFF OFF OFF 54°F (12.2°C) 86°F (30.0°C)

ON OFF OFF 56°F (13.3°C)

OFF ON OFF 58°F (14.4°C)

ON ON OFF 60°F (15.5°C)

OFF

ON OFF ON 64°F (17.7°C)

OFF ON ON 66°F (18.9°C) 74°F (23.3°C)

ON ON ON 68°F (20.0°C) 72°F (22.2°C)

OFF ON 62°F (16.6°C)

Cooling Operation

Heating Operation

Lowest Temp. Highest Temp. Lowest Temp. Highest Temp.

86°F (30.0°C) 86°F (30.0°C) 86°F (30.0°C)

86°F (30.0°C) 86°F (30.0°C) 86°F (30.0°C) 86°F (30.0°C)

54°F (12.2°C) 54°F (12.2°C) 54°F (12.2°C) 54°F (12.2°C) 54°F (12.2°C) 54°F (12.2°C) 54°F (12.2°C) 54°F (12.2°C)

86°F (30.0°C) 84°F (28.9°C) 82°F (27.8°C) 80°F (26.7°C) 78°F (25.5°C) 76°F (24.4°C)

• REMOTE/LOCAL CONTROL

When remote/local switch #1 is on, it allow the unit to operate by the control of Remote Wall Thermostat. The unit control by knobs are not available.

• ENERGY SAVER

The energy saver switch #2 is on. This switch is set at continuous fan to provide continuous fan operation in cool or heat modes. When the switch is off the continuous fan allows continuous circulation of room air and make the more balanced temperature of the room. When the switch is on the fan is on or off with the compressor or with the heater.

• FRONT DESK CONTROL

When the pair wire is connected to the connector LOand LI, the unit can be turned ON or OFF with a switch located at the Front Desk Control panel. When the front desk switch is ON, the fan operate according to the condition of setting without working compressor and heater. When the front desk switch is OFF, the unit can operate according to the setting of controls.

• REMOTE WALL THERMOSTAT

When the wires are connected, the unit will be controlled by a remote wall thermostat. The thermostat connections supply the 24 Volt AC. When you install the digital / electronic thermostat, you must set it to the 24 Volt AC. See the installation Instruction in this manual for the Remote Wall Thermostat.

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GL GH O W Y R CLO LI

Front Desk Switch

LO LI GL GH O W Y R C

Low Fan

High Fan

Reversing V alve

Heater

Compressor

24 Volt-L

24 Volt-N

Wiring Schematic for Remote Heat Pump

Wiring Schematic for Straight Cool Unit.

Note: The following figures show wiring

schematics for heat pump and straight cool units with electric heat, respectively.

Wire # AWG Maximum Length

#22

600ft(180m) #20 900ft(270m) #18 1500ft(450m) #16 2000ft(610m)

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2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Remove the front grille. (See Fig. 1)

2. To remove the front grille, pull out the bottom of the front grille and then lift up. Re-install the component by referring to the removal procedure.

3. To replace the front grille, place the tabs over the top of the unit and push the bottom of front grille until the clips snap into place.

• This Room Air Conditioner (PTAC) discharges air from the top of the unit through reversible, 2-position discharge grille louvers. The unit is shipped from the factory with the discharge grille louvers at an angle of 40˚ off vertical. In an alternate position the louvers will be at an angle of 15˚ off vertical.

To adjust air direction, remove the front grille. Remove the 4 screws that fasten the discharge grille to the front grille.

Flip the discharge grille 180°, then reattach the discharge grille to the front grille with 4 screws.

2. DISASSEMBLY INSTRUCTIONS

— Before the following disassembly, POWER SWITCH is set to OFF and disconnected the power cord.

Figure 1

40˚

15˚

Screws

—10—

2.1.2 CONTROL BOX (Half-Disassembly)

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the three screw which fasten the control box. (See Fig. 2)

3. Pull the control box from the barrier. (See Fig.2)

4. Discharge the capacitor by placing a 20,000 ohm resistor across the capacitor terminals.

5. Disconnect three wire housings in the control box.

6. Pull the control box forward completely.

7. Re-install the components by referring to the removal procedure. (See Fig. 2) (Refer to the circuit diagram found on page 25 in this manual and on the control box.)

2.1.3 CONTROL BOX (Full-Disassembly)

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the 4 screws which fasten the control box cover. (See Fig.3)

3. Disconnect three wire housings in the control box.

4. Remove three screws which fasten the control box assembly.

5. Pull the control box assembly out from the unit.

Figure 2

Figure 3

Figure 7

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2.2 AIR HANDLING PARTS

2.2.1 HEATER ASSEMBLY AND CROSS FLOW FAN

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the control box assembly. (Refer to section 2.1.3)

3. Remove the 3 screws which fasten the net steel. (See Fig. 4)

4. Remove the 3 screws which fasten the electric heater assembly. (Electric heater model only) (See Fig.4).

5. Loosen the hexagon screw with the Hex-wrench (See Fig.5)

6. Remove the 4 screws which fasten the indoor motor and the earth wire. (See Fig. 5. 6)

7. Re-install the components by referring to the removal procedure, above.

2.2.2 FAN

1. Remove the brace.

2. Remove the 4 screws which fasten the condenser with the shroud and the basepan.

3. Move the condenser sideways carefully.

4. Remove the clamp which secures the fan with pliers.

5. Remove the fan. (See Fig. 7)

6. Re-install the components by referring to the removal procedure, above.

Figure 4

Figure 5

Figure 6

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