LG ASNW096FE, ASUW126FUG0, ASNW126F1G0, ASNW126FE, ASNW126F2G0 Service Manual
...
LG
Room Air Conditioner
SERVICE MANUAL
LG
MODELS: ASNW096F1G0
ASNW096FE/V/GG0
ASNW126F1G0
ASNW126FE/V/GG0
ASUW126FUGO
ASNW126F2G0(A12AW2-NF6)
ASUW126FUGO(A12AWU-UF6)
CAUTION
website http://www.lgservice.com
• BEFORE SERVICING THE UNIT, READ THE SAFETY
PRECAUTIONS IN THIS MANUAL.
• ONLY FOR AUTHORIZED SERVICE PERSONNEL.
2 Room Air Conditioner
Air Conditioner Service Manual
TABLE OF CONTENTS
LG Model Name.................................................................................................................................3
Safety Precautions ...........................................................................................................................4
Dimensions .....................................................................................................................................10
Installation.......................................................................................................................................12
Flaring work and connection of piping.........................................................................................15
Checking the drainage and forming the pipings .........................................................................18
Air purging ......................................................................................................................................19
Test running ....................................................................................................................................22
Functions.........................................................................................................................................23
Operation.........................................................................................................................................27
Disassembly....................................................................................................................................40
Troubleshooting Guide ..................................................................................................................42
Schematic Diagram ........................................................................................................................62
Product Specifications ..................................................................................................................68
Exploded View ................................................................................................................................69
Replacement Parts List ..................................................................................................................71
Service Manual 3
LG Model Name
LG Model Name
2006
12 - 345678910
Code Type Code of Model Meaning
1 Producing Center, A~Z L: Chang-won R22 N: India
Refrigerant A: Chang-won R410A Z: Brazil
C: Chang-won R407C D: Indonesia
T: China M: Mexico
K: Turkey R22 V: Vietnam
E: Turkey R410A S: Out Sourcing
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
V: AC Inverter C/O
N: AC Inverter H/P
Q: DC Inverter C/O
W: DC Inverter H/P
4, 5 Capacity 0~9 Cooling/Heating Capacity
Ex. "09" → 9,000 Btu/h
6 Electric Range 1~9 1: 115V/60Hz, A: 220V, 50Hz, 3Phase
A~Z 2: 220V/60Hz B: 208~230V, 60Hz, 3Phase
3: 208-230V/60Hz C: 575V, 50Hz, 3Phase
5: 200-220V/50Hz D: 440~460, 60Hz, 3Phase
6: 220-240V/50Hz E: 265V, 60Hz
7: 110V, 50/60Hz F: 200V, 50/60Hz
8: 380-415V/50Hz
9: 380-415V/60Hz
7 Chassis A~Z Name of Chassis of Unit
8 Look A~Z Look,
Color (Artcool Model)
9 Function A~Z
10 Serial No. 0~9 LG Model De
* ARTCOOL COLOR (SF)
velopment Serial No.
Basic A
Basic+4Way B
Plasma Filter C
Plasma Filter+4 Way D
Tele+LCD E
Tele+LCD+Nano plasma+4Way F
Nano Plasma F+(A/changeove)+A/clean+Low A G
Nano Plasma F+(A/changeove)+A/clean+4way+Low A H
Tele+LED+4way I
Internet J
Plasma F+4Way+Oxy generator K
Nano Plasma F+(A/changeove)+A/clean L
Nano Plasma F+(A/changeove)+A/clean+4way M
Nano Plasma F+(A/changeove)+A/clean+PTC N
Nano Plasma F+(A/changeove)+Autoclean+4way+PTC P
Nano Plasma F+(A/changeove)+A/clean+4way+Low A+PTC Q
Negative ION+A/Clean R
(Nano)Plasma+Negative ION+A/Clean S
4way+(Nano)Plasma F+Negative ION+Healthy dehumidification+A/Clean
T
Nano Plasma F+4Way+(A/changeove)+A/clean+ U
1 Kiss
E Red
V Silver
G Gold
Ex.F → SF Chassis
4 Room Air Conditioner
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.
■ Meanings of symbols used in this manual are as shown below.
This symbol indicates the possibility of death or serious injury.
This symbol indicates the possibility of injury or damage to properties only.
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 or electric
shock.
For electrical work, contact
the dealer, seller, a qualified
electrician, or an Authorized
Service Center.
• There is risk of fire or electric
shock.
Always use the power plug
and socket with the ground
terminal.
• There is risk of electric shock.
Install the panel and the cover
of control box securely.
• There is risk of fire or electric
shock.
Do not modify or extend the
power cord.
• There is risk of fire or electric
shock.
Do not install, remove, or reinstall the unit by yourself
(customer).
• There is risk of fire, electric
shock, explosion, or injury.
Service Manual 5
Safety Precautions
■ Operation
Be cautious when unpacking
and installing the product.
• Sharp edges could cause injury.
Be especially careful of the case
edges and the fins on the condenser and evaporator.
For installation, always contact the dealer or an
Authorized Service Center.
• There is risk of fire, electric
shock, explosion, or injury.
Do not install the product on a
defective installation stand.
• It may cause injury, accident, or
damage to the product.
Be sure the installation area
does not deteriorate with age.
• If the base collapses, the air
conditioner could fall with it,
causing property damage, product failure, and personal injury.
Do not let the air conditioner
run for a long time when the
humidity is very high and a
door or a window is left open.
• Moisture may condense and wet
or damage furnishings.
Take care to ensure that
power cords could not be
pulled out or damaged during
operation.
• There is risk of fire or electrical
shock.
Do not place anything on the
power cord.
• There is risk of fire or electric
shock.
Do not turn the air-conditioner
ON or OFF by plugging or
unplugging the power plug.
• There is risk of fire or electrical
shock.
6 Room Air Conditioner
Safety Precautions
Use a dedicated outlet for this
appliance.
• 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 place a heater or other
appliances near the power
cable.
• There is risk of fire and electric
shock.
Do not allow water to run into
electric parts.
• It may cause There is risk of
fire, failure of the product, or
electric shock.
Do not store or use flammable
gas or combustibles near the
air conditioner.
• There is risk of fire or failure of
product.
Do not use the product in a
tightly closed space for a long
time.
• Oxygen deficiency could occur.
When flammable gas leaks,
turn off the gas and open a
window for ventilation before
turn the product on. DO NOT
use the telephone or turn
switches on or off.
• There is risk of explosion or fire.
Unplug the unit if strange
sounds, odors, or smoke
comes from it.
• There is risk of electrical shock
or fire
Stop operation and close the
window in storm or hurricane.
If possible, remove the air
conditioner from the window
before the hurricane arrives.
• There is risk of property damage, failure of product, or electric shock.
Thinner
Wax
Service Manual 7
Safety Precautions
■ Installation
Do not open the inlet grill of
the product during operation.
(Do not touch the electrostatic
filter, if the unit is so
equipped.)
• There is risk of physical injury,
electric shock, or product failure.
When the product is soaked
(flooded or submerged), contact an Authorized Service
Center.
• There is risk of fire or eletric
shock.
Ventilate the product from
time to time when operating it
together with a stove, etc.
• There is risk of fire or electrical
shock.
Unplug the appliance before
performing cleaning or maintenance.
• There is risk of electrical shock.
When the product is not be
used for a long time, disconnect
the power supply plug or turn
off the breaker.
• There is risk of product damage
or failure, or unintended operation.
Take care to ensure that
nobody could step on or fall
onto the outdoor unit.
• This could result in personal
injury and product damage.
Always check for gas (refrigerant) leakage after installation
or repair of product.
• Low refrigerant levels may
cause failure of product.
Install the drain hose to
ensure that water is drained
away properly.
• A bad connection may cause
water leakage.
Keep level even when
installing the product.
• To avoid vibration or water leakage.
90˚
8 Room Air Conditioner
Safety Precautions
■ Operation
Do not install the product
where the noise or hot air
from the outdoor unit could
damage the neighborhoods.
• It may cause a problem for your
neighbors.
Use two or more people to lift
and transport the air conditioner.
• Avoid personal injury.
Do not install the product
where it will be exposed to
sea wind (salt spray) directly.
• It may cause corrosion on the
product. Corrosion, particularly
on the condenser and evaporator fins, could cause product
malfunction or inefficient operation.
Do not direct airflow at room
occupants. (Don't sit in the
draft.)
• This could damage your health.
Do not use the product for
special purposes, such as
preserving foods, works of
art, etc. It is a consumer air
conditioner, not a precision
refrigeration system.
• There is risk of damage or loss
of property.
Do not block the inlet or outlet
of air flow.
• It may cause product failure.
Use a soft cloth to clean. Do
not use harsh detergents, solvents, etc.
• There is risk of fire, electric
shock, or damage to the plastic
parts of the product.
Do not touch the metal parts
of the product when removing
the air filter. They are very
sharp!
• There is risk of personal injury.
Do not step on or put anyting
on the product. (outdoor
units)
• There is risk of personal injury
and failure of product.
Service Manual 9
Safety Precautions
Always insert the filter securely. Clean the filter every two
weeks or more often if necessary.
• A dirty filter reduces the efficiency of the air conditioner and
could cause product malfunction
or damage.
Do not insert hands or other
objects through the air inlet or
outlet while the air conditioner
is plugged in.
• There are sharp and moving
parts that could cause personal
injury.
Do not drink the water drained
from the unit.
• It is not sanitary and could
cause serious health issues.
Use a firm stool or ladder when cleaning or
maintaining the air conditioner.
• Be careful and avoid personal injury.
Replace the all batteries in the remote control
with new ones of the same type. Do not mix
old and new batteries or different types of batteries.
• There is risk of fire or explosion
Do not recharge or disassemble the batteries.
Do not dispose of batteries in a fire.
• They may burn or explode.
If the liquid from the batteries gets onto your
skin or clothes, wash it well with clean water.
Do not use the remote if the batteries have
leaked.
• The chemicals in batteries could cause burns or
other health hazards.
■ Disuse
10 Room Air Conditioner
Dimensions
Dimensions
Pipe Hole
Fix Hole
Hanger Hole
H
W
D
W mm 600
H mm 600
D mm 146(143)
Model
Dimension
INDOOR
Indoor Unit
This symbol alerts you to the risk of electric shock.
This symbol alerts you to hazards that could cause harm to the
air conditioner.
This symbol indicates special notes.
NOTICE
Symbols Used in this Manual
Service Manual 11
W
L2
L3
L1
D
H
L4
L5
Gas side
(3-way valve)
Liquid side
(2-way valve)
MODEL
DIM unit
W mm 770
H mm 545
D mm 245
L1 mm 285
L2 mm 64
L3 mm 518
L4 mm 10
L5 mm 100
Dimensions
Outdoor Unit
OUTDOOR
12 Room Air Conditioner
Installation
Installation
Indoor unit
• 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.
• Use a stud finder to locate studs to prevent
unnecessary damage to the wall.
Outdoor unit
• 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 30cm. 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 weight of the air conditioner into account and select
a place where noise and vibration are minimum.
• Select a place where the warm air and noise from the air
conditioner do not disturb neighbors.
Rooftop Installations:
• 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.
More than 20cm
More
than 50cm
More than 1.5m
More
than 50cm
• 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.
Pipe Size
Capacity
(Btu/h)
GAS LIQUID
Max.
Length
A (m)
Additional
Refrigerant
(g/m)
Max.
Elevation
B (m)
Standard
Length
(m)
5k~14k
3/8"(Ø9.52) 1/4"(Ø6.35) 4 or 7.5 7 15 20
1/2"(Ø12.7) 1/4"(Ø6.35) 4 or 7.5 7 15 20
1/2"(Ø12.7) 1/4"(Ø6.35) 4 or 7.5 15 30 20
18k~28k 5/8"(Ø15.88) 1/4"(Ø6.35) 4 or 7.5 15 30 20
5/8"(Ø15.88) 3/8"(Ø9.52) 4 or 7.5 15 30 30
30k~38k
5/8"(Ø15.88) 3/8"(Ø9.52) 7.5 15 30 30
3/4"(Ø19.05) 3/8"(Ø9.52) 7.5 15 30 50
If case more than 5m
Outdoor unit
Indoor unit
A
B
Outdoor unit
Indoor unit
A
B
A
Oil trap
Outdoor unit
Indoor unit
B
If piping length is more than 5m
Selection of the Best Location
Piping Length and Elevation
More than 30cm
More than 30cm
More
than 60cm
More than 60cm
More than 70cm
Service Manual 13
Installation
Preparing Work for Installation
Open panel front
1. Pull the upper part of the front panel.
2. Lift up the panel.
3. To detach the front panel, remove the two screws at the lower part.
4. Detach the front panel from the body.
5. To detach the panel, disconnect the connector at the upper part.
Cover pipe and cover side remove
1. Please remove the screw of the center tuning cover.
2. Pull up the side cover of desired connecting direction, then
cover side is separated.
3. Pick the pipe hole of the side cover.
CAUTION: After removing the pipe hole, cut
the burr for safety.
When making pipe path through rear
wall, you don’t need to pick the pipe hole.
NOTICE
Drain hose junction
1. Remove the rubber stopple in the desired drain direction.
2. Insert drain hose into the handle of drain pan, and
join drain hose and connecting hose according to the
figure by.
Panel Front
Connector
Pipe hole
Side cover
Adhesive
Only the
Only the
desired direction
desired direction
Drain
hose
Connecting
part
rubber cap
14 Room Air Conditioner
Installation
Fixing Indoor Unit
• Drill the piping hole with a ø50mm hole core drill.
Drill the piping hole at either the right or the left with
the hole slightly slanted to the outdoor side.
Drill a Hole in the Wall
5-7mm
(0.2~0.3")
Indoor
WALL
Outdoor
Plastic anchors
INSTALLATION GUIDE MAP
10mm
INSTALLATION GU
INSTAIIATION GUIDE MAP
Plastic anchors
INSTALLATION GUIDE MAP
INSTALLATION GUIDE MAP
Hanger hole
(Rear side of
the product)
3. Make a hole with a diameter of 6mm and
depth of 30-35mm by piercing a screw
point.
5. Drive the fore plastic anchors into drilled
points.
7. Hang the hole of product at the upper
screws, and remove the map. (Falling
attention)
9. Check the fixed product with light power.
1. Attach an Installation guide map on the
desired surface.
2. Look at suited horizon by horizontal
meter on the horizontal setting line, and
fix lightly the map by adhesive tape.
4.
Drill the pierted part as a diameter of 50mm
for connecting piping. (In case of piercing
rear surface)
6.
First, Drive the two points of the upper
parts by screws. (Leave 10mm for hanging
the product)
8. Drive the lower parts after facing the hole
of product with plastic anchors, and fix
completely the upper screws.
10.
In case of nothing wrong, connect the
pipe and the wire. (Refer to installation
manual)
I
NSTALLATION GUIDE MAP
Horizontality
Service Manual 15
Flaring work and connection of piping
Flaring work and connection of piping
Flaring work
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.
Check
• Compare the flared work with figure below.
• If flare is noted to be defective, cut off the flared sec-
tion and re-flare it.
• Preparing the indoor unit's piping and drain hose for installation through the wall.
• Route the indoor tubing and the drain hose in the direction
of rear left or right
• 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.
• Carry out flaring work using flaring tool as shown below.
Burr removal
• 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.
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)
Flaring work
• Firmly hold copper pipe in a die in the dimension shown in
the table above.
Bar
Copper pipe
Clamp handle
Red arrow mark
Cone
Yoke
Handle
Bar
"A"
Inclined
Inside is shiny without scratches
Smooth all round
Even length
all round
Surface
damaged
Cracked Uneven
thickness
= Improper flaring =
Pipe
Reamer
Point down
Flare nut
Copper tube
Drain hose
mm inch mm
Ø6.35 1/4 0~0.5
Ø9.52 3/8 0~0.5
Ø12.7 1/2 0~0.5
Ø15.88 5/8 0~1.0
Ø19.05 3/4 1.0~1.3
Outside diameter A
Connection of piping -- Indoor
Copper
pipe
Slanted Uneven Rough
90°
16 Room Air Conditioner
Flaring work and connection of piping
Wrench
Indoor unit tubing
Open-end wrench (fixed)
Connection pipe
Flare nut
Indoor unit tubing Flare nut Pipes
Vinyl tape(narrow)
Adhesive
Drain pipe
Indoor unit drain hose
Plastic bands
Insulation material
Vinyl tape(narrow)
Connection
pipe
Connecting cable
Vinyl tape
(wide)
Wrap with vinyl tape
Indoor
unit pipe
Pipe
Connecting the pipings to the indoor unit and
drain hose to drain pipe.
• Align the center of the pipes and sufficiently tighten
the flare nut by hand.
• Tighten the flare nut with a wrench.
• When extending the drain hose at the indoor unit, install the
drain pipe.
Wrap the insulation material around the connecting portion.
•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.
• Wrap the area which accommodates the rear piping hous-
ing section with vinyl tape.
mm inch kg.m
Ø6.35 1/4 1.8
Ø9.52 3/8 4.2
Ø12.7 1/2 5.5
Ø15.88 5/8 6.6
Ø19.05 3/4 6.6
Outside diameter Torque
CAUTION: 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.
Connecting
cable
Gas side piping
Liquid side piping
Drain hose
Loop
CAUTION: Installation Information
For right piping. Follow the instruction
below.
Good case
• Press on the upper side of clamp and unfold the tubing to downward slowly.
Service Manual 17
Flaring work and connection of piping
Bad case
• Following bending type from left to right may cause
damage to the turbing.
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.
Connection of the pipes-Outdoor
mm inch kg.m
Ø6.35 1/4 1.8
Ø9.52 3/8 4.2
Ø12.7 1/2 5.5
Ø15.88 5/8 6.6
Ø19.05 3/4 6.6
Outside diameter Torque
Outdoor unit
Gas side piping
(Bigger diameter)
Liquid side
piping
(Smaller
diameter)
Torque wrench
18 Room Air Conditioner
Checking the drainage and forming the pipings
Checking the drainage and forming the pipings
Checking the drainage Form the piping
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.
Form the piping by wrapping the connecting
portion of the indoor unit with insulation material and secure it with two kinds of vinyl tapes.
• 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.
• Secure the tapped piping along the exterior wall using saddle or equivalent.
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.
• 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.
Drain piping
• The drain hose should point downward for easy drain flow.
• Do not make drain piping.
Downward slope
Do not raise
Accumulated
drain water
Tip of drain hose
dipped in water
Air
Waving
Water
leakage
Water
leakage
Ditch
Less than
50mm gap
Water
leakage
Taping
Drain hose
Pipings
Connecting cable
Trap is required to prevent water
from entering electrical parts.
Seal small openings
around pipings with a
gum type sealer.
Seal a small opening
around the pipings
with gum type sealer.
Trap
Trap
Service Manual 19
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.
• Moisture in the refrigerant circuit may freeze and block cap-
illary tubing.
• Water may lead to corrosion of parts in the refrigeration
system.
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.
• 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.
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.
Leak test
• Connect the manifold valve(with pressure gauges) and dry
nitrogen gas cylinder to this service port with charge hoses.
• 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.
Air Purging
Air purging
Air purging with vacuum pump
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.
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.
Lo Hi
Indoor unit
Outdoor unit
Manifold valve
Charge hose
Nitrogen gas
cylinder(in vertical
standing position)
Pressure
gauge
20 Room Air Conditioner
Air purging
Evacuation
• 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.
• 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.
• 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.
(1) Remove the caps from the 2-way and 3-way valves.
(2) Remove the service-port cap from the 3-way valve.
(3) To open the 2-way valve turn the valve stem counter-
clockwise 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.
(5) If bubbles come out, the pipes have leakage.
Soap water method
Gas side
Liquid side
Cap
Hexagonal wrench
2-way valve
(Open)
3-way valve
(Close)
Required time for evacuation when 30 gal/h vacuum
pump is used
10 min. or more 15 min. or more
If tubing length is less than 10m (33 ft)
if tubing length is longer than 10m (33 ft)
Indoor unit
Outdoor unit
Lo Hi
Manifold valve
Vacuum pump
Pressure
gauge
Open
Close
Service Manual 21
Air purging
1. First, Check the side cover assembly exactly, and fix
the power cord in the bottom groove of cover side
left.
2. Assemble connecting lead wire with controller, fix the
upper part of panel front, and match the lower part of
panel front.
3. Screw up panel front, and suspend the hook of panel
front in the groove.
Panel Front
Connector
Panel Front Assembly
22 Room Air Conditioner
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.
Prepare remote controller
1. Remove the battery cover
by pulling it according to the
arrow direction.
2. Insert new batteries making
sure that the (+) and (–) of
battery are installed correctly.
3. Reattach the cover by
pushing it back into position.
• Use 2 AAA(1.5volt) batteries. Do not use
rechargeable batteries.
• Remove the batteries from the remote
control if the system is not going to be
used for a long time.
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 antivibration bushing.
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).
4. For reference; the gas side pressure of optimum
condition is as below.(Cooling)
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.
NOTICE
NOTICE
Bolt
Tubing connection
Discharge
temperature
Discharge air
Intake temperature
R-22 35°C (95°F) 4~5kg/cm2G(56.8~71.0 P.S.I.G.)
R-410A 35°C (95°F) 8.5~9.5kg/cm
2
G(120~135 P.S.I.G.)
Outside ambient
TEMP.
Refrigerant
The pressure of the gas side
service valve.
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.
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).
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.
PUMP DOWN
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