LG AS-W1264GH0, AS-W0964GH0, AS-W1865DH0, AS-W091264DH0, AS-W1424DH0 User Manual

Room Air Conditioner

SERVICE MANUAL

MODELS: AS-W0964DH0

AS-W1264DH0 AS-W1865DH0 AS-W0964GH0 AS-W1264GH0 AS-W1224DH0 AS-W1424DH0 AS-W1825DH0

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 ...........................................................................................................................5

Dimensions ...............................................................................................................................

......10

Installation...............................................................................................................................

........14

Flaring work and connection of piping.........................................................................................16

Connecting the cable between indoor unit and outdoor unit.....................................................21

Checking the drainage and forming the pipings.........................................................................23

Air purging ......................................................................................................................................24

Test running ....................................................................................................................................26

Functions.........................................................................................................................................27

Operation.........................................................................................................................................30

Disassembly....................................................................................................................................41

Troubleshooting Guide ..................................................................................................................44

Schematic Diagram ........................................................................................................................65

Product Specifications ..................................................................................................................73

Exploded View ................................................................................................................................75

Replacement Parts List..................................................................................................................78

Service Manual 3

LG Model Name

2003

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

Ex. LSP → SP Chassis

8 Look A~Z Look,

Color (Artcool Model)

9 Function A~Z

10 Serial No. 0~9 LG Model De

* ARTCOOL COLOR

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

Nano Plasma F+4Way+(A/changeove)+A/clean+ U

R Mirror W White B Blue D Wood M Metal C Cherry

N Walnut A Gogh S Sisley Q Quran K Mecca

4 Room Air Conditioner

LG Model Name

2004~

12 -345678910

Code Type Code of Model Meaning

1 Producing Center, A~Z

L Chang_won R22 A Chang_won R410A C Chang_won R407C T China K Turkey R22 E Turkey R410A H Thailand

N India Z Brazil D Indonesia X Mexico V Vietnam S Out sourcing

Refrigerant

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

CHASSIS 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

, 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 Look,

Color (Artcool Model)

9 Function A~Z

10 Serial No. 0~9 LG Model De

* ARTCOOL COLOR

velopment Serial No.

R Mirror W White B Blue D Wood M Metal C Cherry

S4/S5

S6 SQ SR

Basic A Basic+4Way B Plasma Filter C Plasma Filter+4 Way D Tele+LCD E Tele+LCD+Nano plasma+4Way F NBF F+(A/changeove)+A/clean+Low A G NBF F+(A/changeove)+A/clean+4way+Low A H Tele+LED+4way I Internet J Plasma F+4Way+Oxy generator K NBF F+(A/changeove)+A/clean L NBF F+(A/changeove)+A/clean+4way M NBF F+(A/changeove)+A/clean+PTC N NBF F+(A/changeove)+Autoclean+4way+PTC P NBF F+(A/changeove)+A/clean+4way+Low A+PTC Q (Nano)Plasma+ION+A/Clean S 4way+(Nano)Plasma F+

Negative ION+Healthy dehumidification

+A/Clean T Nano Plasma F+4Way+(A/changeove)+A/clean+Oxy generator U 4way+(Nano)Plasma F+Negative ION+Healthy dehumidification+A/Clean+Oxy generator

V Dry contact W Wire remocon 8

Service Manual 5

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.

Do not use damaged power cords, plugs, or a loose socket.

Always use the power plug and socket with the ground terminal.

• There is risk of fire of electric shock. • There is risk of electric shock.

Install the panel and the cover of control box securely.

Do not modify or extend the power cord.

• There is risk of fire of electric shock. • No grounding may cause electric shock.

■ Installation

6 Room Air Conditioner

Safety Precautions

Do not install the product on a defective installation stand.

Be sure the installation area does not deteriorate with age.

• It may cause injury, accident, or damage to the

product.

• If the base collapses, the air conditioner could fall with it, causing property damage, product failure, and personal injury.

• Sharp edges could cause injury. Be especially careful of the case edges and the fins on the condenser and evaporator.

•

There is risk of fire, electric shock, explosion, or injury.

Be cautious when unpacking and installing the product.

For installation, always contact the dealer or an Authorized service center

For re-installation of the installed product, always contact a dealer or an authorized service center.

Do not install, remove, or re-install the unit by yourself.

• There is risk of fire, electric shock, explosion, or injury.

Service Manual 7

Safety Precautions

■ Operation

Do not turn the air-conditioner ON or OFF by plugging or unplugging the power plug.

Use a dedicated outlet for this appliance.

• There is risk of fire or electrical shock. • 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.

Do not place a heater or other appliances near the power cable.

• There is risk of fire or electrical shock. • There is risk of fire and electric shock.

Do not allow water to run into electrical parts. Do not store or use flammable gas or com-

bustibles near the air conditioner.

• There is risk of fire, failure of the product, or electric shock.

• There is risk of fire or failure of product.

Wax

Thinner

8 Room Air Conditioner

Always check for gas (refrigerant) leakage after installation or repair of product.

Install the drain hose to ensure that water is drained away pro perly.

• Low refrigerant levels may cause failure of product. • A bad connection may cause water leakage.

Keep level even when installing the product. Use two or more people to lift and transport

the air conditioner.

• To avoid vibration or water leakage. • Avoid personal injury.

■ Installation

90˚

Unplug the unit if strange sounds, odors, or smoke comes from it.

Be cautious that water could not enter the product.

• There is risk of electric shock or fire. • There is risk of fire, electric shock, or product damage.

Safety Precautions

Service Manual 9

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 plastic parts of the product.

• There is risk of personal injury.

Do not step on or put anyting on the product. (outdoor units)

Do not insert hands or other objects through the air inlet or outlet while the air conditioner is plugged in.

• There is risk of personal injury and failure of product. • There are sharp and moving parts that could cause

personal injury.

■ Operation

Wax

Safety Precautions

10 Room Air Conditioner

Dimensions

Installation plate

W mm 840

H mm 270 D mm 153

Model

Dimension

7k, 9k, 12k, 14k Btu Series

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.

Symbols Used in this Manual

NOTICE

Service Manual 11

Dimensions

Installation plate

W mm 1090

H mm 300 D mm 178

Model

Dimension

18k, 24k Btu Series

12 Room Air Conditioner

Gas side

(3-way valve)

Liquid side

(2-way valve)

MODEL

DIM unit

W mm 770

H mm 540

D mm 245 L1 mm 285 L2 mm 65 L3 mm 518 L4 mm 10 L5 mm 100

Dimensions

Outdoor Unit

7k, 9k, 12k, 14k Btu Series

Dimensions

Service Manual 13

L7 L6 L8 L9

L10L11

L4L5

Gas side

Liquid side

MODEL

DIM

W mm 870

H mm 655

D mm 320 L1 mm 370 L2 mm 340 L3 mm 25 L4 mm 630 L5 mm 25 L6 mm 546 L7 mm 162 L8 mm 162 L9 mm 54

L10 mm 74.5 L11 mm 79

18k, 24k Btu Series

14 Room Air Conditioner

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.

• 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.

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 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.

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 10cm

More than

5cm

More than 2.3m

More than

5cm

• 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.

Grade

Clearance(cm)

5K~28K 10 5

30K~38K 30 12

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 or7.5 7 15 20 1/2"(Ø12.7) 1/4"(Ø6.35) 4 or7.5 7 15 20 1/2"(Ø12.7) 1/4"(Ø6.35) 4 or7.5 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) 4or 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

Outdoor unit

Indoor unit

Oil trap

Outdoor unit

Indoor unit

Selection of the Best Location

Piping Length and Elevation

Install the indoor unit on the wall where the height from the floors more than 2.3 meters.

More than 10cm More than 10cm

More than 60cm

More than 70cm

Service Manual 15

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.

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.

• 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.

• 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.

How to Fix Installation Plate Drill a Hole in the Wall

Drain hose junction

• Remove the rubber stopple in the desired drain direction.

• Insert drain hose into the handle of drain pan, and join drain hose and connecting hose according to the figure by.

Installation Plate

Type "A" screw

Chassis

Hook

5-7mm

(3/16"~5/16")

Indoor

WALL

Outdoor

Installation plate

Left rear piping Right rear piping

Ø70mm

Connecting

part

Adhesive

Drain hose

Only the desired direction

ABCD

7k, 9k, 12k, 14k 75 65 105 65

18k, 24k 105 65 260 65

CHASSIS

(Grade)

Distance (mm)

16 Room Air Conditioner

Flaring work and connection of piping

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.

• Remove the plastic tubing retainer(see illustration below) and pull the tubing and drain hose away from chassis.

• Replace the plastic tubing holder in the original position.(Optional)

• 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 =

Drain hose

Pipe

Reamer

Point down

Flare nut

Copper tube

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

When install, make sure that the remaining parts must be removed clearlysoasnottodamagethepiping and drain hose, especially power cord and connecting cable.

Copper

pipe

Slanted Uneven Rough

90°

Service Manual 17

Flaring work and connection of piping

Route the indoor tubing and the drain hose in the direction of rear right.

Drain hose

Connecting

cable

Vinyl tape(narrow)

Connection pipe

Connecting cable

Vinyl tape (wide)

Wrap with vinyl tape

Indoor unit pipe

Pipe

Plastic bands

Insulation material

Vinyl tape(narrow)

Adhesive

Drain pipe

Indoor unit drain hose

Wrench

Indoor unit tubing

Open-end wrench (fixed)

Connection pipe

Flare nut

Indoor unit tubing Flare nut Pipes

Drain hose

Connecting pipe

Connecting cable

Tape

Drain hose

Insert the connecting cable into the indoor unit from the outdoor unit through the piping hole.

• Do not connect the cable to the indoor unit.

• Make a small loop with the cable for easy connection later.

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.

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

• 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.) Ensurethatthehooksareproperlyseatedontheinstallation plate by moving it left and right.

Press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots(clicking sound).

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 housing 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

For right rear piping

18 Room Air Conditioner

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.

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.

• 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 heat insulation and the indoor unit pipe heat insulation material. Bind them together with vinyl tape so that there is no gap.

Route the indoor tubing and the drain hose to the required piping hole position.

Insert the piping, drain hose, and the connecting cable into the piping hole.

Insert the connecting cable into the indoor unit.

• Don't connect the cable to the indoor unit.

• Make a small loop with the cable for easy connection later.

Indoor unit installation

• 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.

Tape the drain hose and the connecting cable.

• Connecting cable

Drain pipe

Connecting cable

Wrap with vinyl tape

Drain hose

Pipe

Vinyl tape(wide)

Indoor unit tubing Flare nut Pipes

Installation plate

Spacer

Indoor unit

8cm

Plastic bands

Insulation material

Vinyl tape

Adhesive

Drain hose

Indoor unit drain hose

(narrow)

Wrench

Indoor unit tubing

Connection pipe

Flare nut

Open-end wrench (fixed)

For left rear piping

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

Service Manual 19

Installation Information (For left piping)

• Good case For left piping. Follow the instruction below.

• Press on the upper side of clamp. ( )

Flaring work and connection of piping

• Wrap the area which accommodates the rear piping housing section with vinyl tape.

Indoor unit installation

• Remove the spacer.

• Ensure that the hooks are properly seated on the installa-

tion plate by moving it left and right.

Press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots(clicking sound).

• 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.

Reroute the pipings and the drain hose across the back of the chassis.

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.

Vinyl tape(narrow)

Connection pipe

Connecting cable

Indoor unit piping

Pipe

Vinyl tape (wide)

Wrap with vinyl tape

Drain hose

Vinyl tape(narrow)

Pipe

Wrap with vinyl tape(wide)

Piping for passage through piping hole

Tubing holder

Drain hose

Connecting

cable

• Unfold the tubing to downward slowly. ( )

• Bend the tubing to the left side of chassis.

20 Room Air Conditioner

Flaring work and connection of piping

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.

• Bad case

• Following bending type from right to left could cause

problem of pipe damage.

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

Service Manual 21

Connect the cable to the Indoor unit.

Connecting the cable between indoor unit and outdoor 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.

If a power plug is not used, provide a circuit breaker between power source and the unit as shown by.

The power cord connected to the "A" unit should be selected according to the following specifications(Type "B" approved by HAR or SAA).

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).

Air

Conditioner

Main power source

7k 9k~14k 18k 24k

0.75 1.0 1.5 2.5

Unit(A) Indoor Indoor Indoor Indoor

Cable Type(B) H05VV-F H05VV-F H05VV-F H05VV-F

NORMAL CROSS

-SECTIONAL AREA

Grade

(mm2)

7k 9k~14k 18k 24k

0.75 1.0 1.5 2.5

Cable Type(B) H07RN-F H07RN-F H07RN-F H07RN-F

NORMAL CROSS

-SECTIONAL AREA

Grade

(mm2)

Circuit Breaker

Use a circuit breakerortime delay fuse.

22 Room Air Conditioner

Connecting the cable between indoor unit and outdoor unit

Remove the control cover from the unit by loosening the screw.

Connect the wires to the terminals on the control board individually.

Secure the cable onto the control board with the cord clamp.

Refix the control cover to the original position with the screw.

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.

Terminal block

Over 5mm

Cover control

Connecting cable

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 func-

tion 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.

Outdoor Unit

Connect the cable to the outdoor unit

5k~14k 18k 24k~28k 30k, 32k 36k, 38k

15 20 30 30 40

Circuit

Breaker

(A)

Grade

Service Manual 23

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.

• 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.

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.

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.

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.

Pull the right and the left side.

Downward slope

Do not raise

Accumulated drain water

Tip of drain hose dipped in water

Air

Waving

Water leakage

Ditch

Less than 50mm gap

Water leakage

Taping

Drain hose

Pipings

Connecting cable

Trap is required to prevent water from entering into electrical parts.

Seal small openings around pipings with a gum type sealer.

Seal a small opening around the pipings with gum type sealer.

Trap

24 Room Air Conditioner

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

Service Manual 25

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

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