LG AS-W096E1G0, AS-W1825DH0, AS-W1865DH0, AS-W126E1G0, AS-W1224DH0 Service Manual
...
LG
Room Air Conditioner
SERVICE MANUAL
LG
MODELS: AS-W0964DH0/GH0
AS-W1264DH0/GH0
AS-W1865DH0
AS-W1224DH0
AS-W1424DH0
AS-W1825DH0
AS-W096E1G0
AS-W126E1G0
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
Connecting the cable between indoor unit and outdoor unit.....................................................24
Checking the drainage and forming the pipings.........................................................................26
Air purging ......................................................................................................................................27
Test running....................................................................................................................................29
Functions.........................................................................................................................................30
Operation.........................................................................................................................................33
Disassembly....................................................................................................................................44
Troubleshooting Guide ..................................................................................................................47
Schematic Diagram ........................................................................................................................67
Product Specifications ..................................................................................................................76
Exploded View ................................................................................................................................79
Replacement Parts List..................................................................................................................83
Service Manual 3
LG Model Name
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. 4 → S4 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
T
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
G
1
K
L
G
M
N
D
P
Division
Panel Type(Deluxe)
Grille Type
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. 4→S4 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/SD
SE
S6
SQ
SR
ST
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
D
H
W
Installation plate
Installation plate
Type 1.
Type 2.
10 Room Air Conditioner
Dimensions
Dimensions
W mm 840 895
H mm 270 282
D mm 153 165
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.
NOTICE
Symbols Used in this Manual
Service Manual 11
Dimensions
D
H
W
Installation plate
Installation plate
Type 1.
Type 2.
W mm 1090
H mm 300
D mm 178
Model
Dimension
18k, 24k Btu Series
12 Room Air Conditioner
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 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
W
L7 L6 L8 L9
D
L1
L2
L3
L10L11
L4L5
H
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
Installation
Indoor unit
1. Do not have any heat or steam near the unit.
2. Select a place where there are no obstacles in front
of the unit.
3. Make sure that condensation drainage can be conveniently routed away.
4. Do not install near a doorway.
5. Ensure that the interval between a wall and the left
(or right) of the unit is more than 50cm. The unit
should be installed as high as possible on the wall,
allowing a minimum of 10cm from ceiling.
6. Use a stud finder to locate studs to prevent unnecessary damage to the wall.
Outdoor unit
1. 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.
2. 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.
3. Do not place animals and plants in the path of the
warm air.
4. Take the weight of the air conditioner into account
and select a place where noise and vibration are minimum.
5. Select a place where the warm air and noise from the
air conditioner do not disturb neighbors.
Select the best Location
More than 10cm
More than
5cm
More than 2.3m
More than
5cm
Install the indoor unit on the wall where the height from the floor is more than 2.3 meters.
More than 10cm More than 10cm
More
than 60cm
More than 60cm
More than 70cm
Service Manual 15
Installation
Piping Length and Elevation
7k, 8k, 9k 3/8" 1/4" 4 or 7.5 7 15 20
11k, 12k, 14k
3/8" 1/4" 4 or 7.5 7 15 20
1/2" 1/4" 4 or 7.5 7 15 20
1/2" 1/4" 4 or 7.5 15 30 20
18k, 24k, 26k 5/8" 1/4" 4 or 7.5 15 30 20
5/8" 3/8" 4 or 7.5 15 30 30
Pipe Size
Capacity
(Btu/h)
GAS LIQUID
Max.
Length A (m)
Additional Refrigerant
(g/m)
Max.
Elevation B (m)
Standard
Length (m)
Outdoor unit
Indoor unit
A
B
Outdoor unit
Indoor unit
A
B
A
Oil trap
Outdoor unit
Indoor unit
B
If the piping length is more
10 Meters and the outdoor
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.
16 Room Air Conditioner
Installation
The wall you select should be strong and solid
enough to prevent vibration
1. Mount the installation plate on the wall with
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.
Fixing Installation Plate
Installation Plate
Type "A" screw
Chassis
Hook
Installation plate
Left rear piping Right rear piping
Ø70mm
Ø70mm
DB
A
C
• 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.
Drill a Hole in the Wall
5-7mm
(3/16"~5/16")
Indoor
WALL
Outdoor
ABCD
S4 73 55 82 55
S5 121 62 258 62
CHASSIS
(Grade)
Distance (mm)
ABCD
S4 50 105 59 105
SE 65 110 85 110
S5 95 122 235 122
CHASSIS
(Grade)
Distance (mm)
Installation plate
Left rear piping Right rear piping
Ø70mm
Ø70mm
D
B
A
C
Type 1.
Type 1.
Type 2.
Type 2.
Service Manual 17
Installation
Flaring Work
Main cause for gas leakage is due to defect in flaring work. Carry out correct flaring work in the following procedure.
Cut the pipes and the cable.
1. Use the piping kit accessory or the pipes purchased locally.
2. Measure the distance between the indoor and the outdoor
unit.
3. Cut the pipes a little longer than measured distance.
4. Cut the cable 1.5m longer than the pipe length.
Burrs removal
1. Completely remove all burrs from the cut cross section of
pipe/tube.
2. 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
1. Firmly hold copper pipe in a die in the dimension shown in the table below.
2. Carry out flaring work with the flaring tool.
Copper
pipe
90°
Slanted Uneven Rough
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
Bar
Copper pipe
Clamp handle
Red arrow mark
Cone
Yoke
Handle
Bar
"A"
18 Room Air Conditioner
Installation
Check
1. Compare the flared work with the figure by.
2. If a flared section is defective, cut it off and do flaring
work again.
Indoor
1. Prepare the indoor unit's piping and drain hose for installation through the wall.
2. Remove the plastic tubing retainer(see the illustration
by) and pull the tubing and drain hose away from
chassis.
3. Replace only the plastic tubing holder 1, not the holder 2 in the original position.
1. Route the indoor tubing and the drain hose in the
direction of rear right.
2.
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 connec-
tion later.
3. 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 uper side
can cause drain pan to overflow inside the unit.
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.
Inclined
Inside is shiny without scratches
Smooth all round
Even length
all round
Surface
damaged
Cracked Uneven
thickness
= Improper flaring =
Connecting the Piping
For right rear piping
Drain hose
Connecting
pipe
Connecting cable
Tape
Drain hose
Service Manual 19
Installation
4. 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.) Ensure that the hooks are properly
seated on the installation 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 piping to the indoor unit and drain
hose to drain pipe.
1. Align the center of the pipes and sufficiently tighten
the flare nut by hand.
2. Tighten the flare nut with a wrench.
3. Mount the clamp on the boss with a type "B"
screw.(optional)
4. When extending the drain hose at the indoor unit,
install the drain pipe.
Wrap the insulation material around the connecting
portion.
1. Overlap the connection pipe insulation material and
the indoor unit pipe insulation material. Bind them
together with vinyl tape so that there may be no gap.
2. Wrap the area which accommodates the rear piping
housing section with vinyl tape.
3. Bundle the piping and drain hose together by wrap-
ping them with vinyl tape for enough to cover where
they fit into the rear piping housing section.
Drain hose
Connecting
cable
Indoor unit tubing Flare nut Pipes
Wrench
Indoor unit tubing
Open-end wrench (fixed)
Connection pipe
Flare nut
Vinyl tape(narrow)
Adhesive
Drain pipe
Indoor unit drain hose
Drain hose
Clamp
Boss
Type "B" screw
Plastic bands
Insulation material
Vinyl tape(narrow)
Connection pipe
Connecting cable
Vinyl tape (wide)
Wrap with vinyl tape
Indoor unit pipe
Pipe
Wrap with vinyl tape
Drain hose
Pipe
Vinyl tape(wide)
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
Outside diameter Torque
20 Room Air Conditioner
Installation
1. Route the indoor tubing and the drain hose to the
required piping hole position.
2. Insert the piping, drain hose, and the connecting
cable into the piping hole.
3.
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 connec-
tion later.
4. Tape the drain hose and the connecting cables.
5. 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.
Connecting the piping to the indoor unit and the
drain hose to drain pipe.
1. Align the center of the pipes and sufficiently tighten
the flare nut by hand.
2. Tighten the flare nut with a wrench.
3. When extending the drain hose at the indoor unit,
install the drain pipe.
For left rear piping
Drain pipe
Connecting
cable
1 2
Installation plate
Spacer
Indoor unit
8cm
Indoor unit tubing Flare nut Pipes
Wrench
Indoor unit tubing
Connection pipe
Flare nut
Open-end wrench (fixed)
Vinyl tape
Adhesive
Drain hose
Indoor unit drain hose
(narrow)
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
Outside diameter Torque
Service Manual 21
Installation
Wrap the insulation material around the connecting
portion.
1. Overlap the connection pipe heat insulation and the
indoor unit pipe heat insulation material. Bind them
together with vinyl tape so that there may be no gap.
2. Wrap the area which accommodates the rear piping
housing section with vinyl tape.
3. 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.
Indoor unit installation
1. Remove the spacer.
2. Ensure that the hooks are properly seated on the
installation plate by moving it left and right.
3. Press the lower left and right sides of the unit against
the installation plate until the hooks engage into their
slots(clicking sound).
Plastic bands
Insulation material
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
Drain hose
Connecting
cable
22 Room Air Conditioner
Installation
Installation Information. For left piping. Follow the instruction below.
Good case
• Press on the upper side of clamp and unfold the tubing to downward slowly.
Bad case
• Following bending type from right to left may cause damage to the tubing.
Service Manual 23
Installation
Outdoor
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.
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
Liquid side piping
(Smaller diameter)
Gas side
piping
(Bigger
diameter)
Torque wrench
24 Room Air Conditioner
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
breaker or time
delay fuse.
Connecting the cable between indoor unit and outdoor unit
Service Manual 25
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
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
Connecting the cable between indoor unit and outdoor unit
26 Room Air Conditioner
Checking the drainage and forming the pipings
Checking the drainage Form the piping
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.
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.
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
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
Trap
Checking the drainage and forming the pipings
Service Manual 27
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
28 Room Air Conditioner
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
Air purging
Service Manual 29
Test running
Test Running
1. Check that all tubing and wiring have been properly con-
nected.
2. Check that the gas and liquid side service valves are fully
open.
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.
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.
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
- 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.
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)
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/cm2G(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
Power
button
30 Room Air Conditioner
Functions
• Room temperature sensor. (Thermistor)
• Pipe temperature sensor. (Thermistor)
• Maintain the room temperature in accordance with the Setting Temp.
• Indoor fan is delayed for 5 sec at the starting.
• Restarting is for approx. 2 minutes.
• Super High, High, Med, Low
--- Lights up in operation
--- Lights up in Timer Mode or Sleep Mode
--- Lights up in Preheat Mode or Defrost Mode
--- Lights up in Plasma Air Clean Mode
--- Lights up in during Energy-Saving Cooling Mode Operation (Optional)
Indoor Unit
Operation ON/OFF by Remote controller
Sensing the Room Temperature
Room temperature control
Starting the Current Contro
l
Time Delay Safety Control
Indoor Fan Speed Control
Operation indication Lamps (LED)
Cooling Mode Operation
Healty dehumidification Mode Operation
Heating Mode Operation
Jet Cool Mode Operation
Jet Heat Mode Operation
Energy Saving Cooling Mode Operation
Functions
Service Manual 31
Functions
• Both the indoor and outdoor fan stops during defrosting.
Defrost(Deice) Control (Heating)
Hot-start Control (Heating)
Heater (Optional)
Plasma
Auto Clean(Optional)
Horizontal airflow Direction Control(Optional)
Energy-Saving Control(Optional)
Auto Changeover
• The fan is switched to S-Low(Cooling), low(Heating) speed.
• The unit will be stopped after 1, 2, 3, 4, 5, 6, 7 hours.
• The fan is switched to intermittent or irregular operation
• The fan speed is automatically switched from high to low speed.
• The louver can be set at the desired position or swing up and down automatically.
Sleep Mode Auto Control
Natural Air Control by CHAOS Logic
Airflow Direction Control
• 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.
• The indoor fan stops until the evaporator pipe temperature will be reached at 30°C.
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