LG AS-W1863 Series, AS-W2463 Series Svc Manual

Universal Air Conditioner

SVC MANUAL(Exploded View)

MODEL : AS-W1863_ Series

AS-W2463_ Series

CAUTION

Before Servicing the unit, read the safety precautions in General SVC manual. Only for authorized service personnel.

Internal Use Only

http://biz.lgservice.com

- 2 -

LGE Internal Use Only

Air Conditioner Service Manual

TABLE OF CONTENTS

LG Model Name ...............................................................................................................................................3

Safety Precautions..........................................................................................................................................5

Dimensions .....................................................................................................................................................9

Symbols Used in this Manual.....................................................................................................................9

Indoor Unit..................................................................................................................................................9

Outdoor Unit.............................................................................................................................................10

Product Specifications ................................................................................................................................11

Installation .....................................................................................................................................................13

Select the Best Location .........................................................................................................................13

Piping Length and Elevation.....................................................................................................................14

Fixing Installation Plate ............................................................................................................................14

Drill a Hole in the Wall..............................................................................................................................15

Flaring Work.............................................................................................................................................15

Connection of Piping ................................................................................................................................16

Connecting the Cables.............................................................................................................................22

Checking the Drainage.............................................................................................................................24

Forming the Piping ...................................................................................................................................25

Air Purging ...............................................................................................................................................26

Test Running ............................................................................................................................................28

Functions .......................................................................................................................................................30

Operation .......................................................................................................................................................33

Disassembly ..................................................................................................................................................47

Indoor Unit................................................................................................................................................47

Schematic Diagram.......................................................................................................................................50

Wiring Diagram.........................................................................................................................................50

Components Location ..............................................................................................................................52

Troubleshooting Guide .................................................................................................................................56

Refrigeration Cycle Diagram ....................................................................................................................56

Pipe Length and the Elevation .................................................................................................................57

2-way, 3-way Valve ...................................................................................................................................58

Cycle Parts...............................................................................................................................................65

Self-diagnosis Function............................................................................................................................66

Electronic Parts ........................................................................................................................................68

Exploded View...............................................................................................................................................79

Indoor Unit................................................................................................................................................79

Outdoor Unit.............................................................................................................................................80

- 3 -

LGE Internal Use Only

LG Model Name

12

3456789

Code Type Code of Model Meaning

1,2 Type of Airconditioner A~Z LS: LG Split Type Airconditioner

3 Chassis A~Z Name of toll of Unit

Ex. LS-R ➔ S R Chassis

4,5 Capacity(Btu/h) 1~9 Cooling/Heating Capacity

Ex. "09" ➔ 9,000Btu/h

6 Electric Range 1~9 Electric Standard

1 ➔ 115V/60Hz 6 ➔ 220~240V/50Hz 2 ➔ 220V/60Hz 7 ➔ 110V, 50/60Hz 3 ➔ 208~230V/60Hz 8 ➔ 380~415V/50Hz 5 ➔ 200~220V/50Hz 9 ➔ 380~415V/60Hz

7 Serial No. 0~9

A~Z

8 Cooling/Heating A~Z

9 LG/OEM Brand A~Z L: LG Brand M: 1st OEM Brand

G: 2nd LG Brand N: 2nd OEM Brand

-

Basic A 0 Plasma Filter B 1 Auto Swing

+ Plasma Filter C 2 Telephone + LED Display D 3 Telephone + LCD Display E 4 Auto Swing

+ Plasma Filter + Telephone + LCD

F5 Low Ambient + Ambient/change G 6 Plasma Filter + Low Ambient + Ambient/change

H7 Internet J 8 Auto Swing + Plasma Filter + Oxygen Generator

K9 Auto Swing + Soft Start ZL Auto Swing + Star Rating M Y Auto Swing + Star Rating + Plasma Filter N X Auto Swing + Soft Start + Star Rating P W Auto Swing + Soft Start + Star Rating 4 + Plasma

QV Auto Swing + Telephone + LCD R U Auto Swing + Telephone + LCD + Soft Start

ST

C/O

C

A

D

G

K

H/P

H

B

E

J

L

E/H+C/O

X

5

7

-

E/H+H/P

Y

6

8

-

C/O

F

M

Q

-

H/P

R

P

S

-

C/O

V

W

1

3

H/P

N

Y

2

4

H/PTH/P

U

INDOOR

BASIC

PLASMA

GOLD FIN

OUTDOOR

BASIC

GOLD FIN

BASIC

GOLD FIN

UNIT

R22

HFC R22+AC INV.

HFC+AC

INV.

HFC+DC

INV.

2002

- 4 -

LGE Internal Use Only

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. 1~9 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

2003~2004

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LGE Internal Use Only

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.

• 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.

■ Installation

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.

Be cautious when unpacking and installing the product.

• Shape edges could cause injury. Be especially careful of the sharp edges.

- 6 -

LGE Internal Use Only

Safety Precautions

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.

Always install a dedicated circuit and breaker.

• Improper wiring or installation may cause fire or electric shock

Use the correctly rated breaker or fuse.

• There is risk of fire or electric shock.

■ Operation

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

• There is risk of fire or electric shock.

Use a dedicated outlet for this appliance.

• There is risk of fire or electric shock.

Grasp the plug to remove the cord from the outlet. Do not touch it with wet hands.

• There is risk of fire or electric shock.

- 7 -

LGE Internal Use Only

Safety Precautions

■ Installation

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

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

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.

Be cautious that water could not enter the product.

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

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

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

Do not allow water to run into electric part.

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

Do not store of use flammable gas or combustibles near the air conditioner.

• There is risk of fire or failure of product.

Wax

Thinner

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 -

LGE Internal Use Only

Safety Precautions

■ Operation

Use two or more people to lift and transport the air conditioner

• Avoid personal injury.

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 anything on the product. (outdoor unit)

• There is risk of personal injury and failure of product.

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

• There are sharp and moving parts that could cause personal injury.

Dimensions

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

Installation plate

D

H

W

MODEL

DIM Unit

W mm 1170

H mm 315

D mm 173

18k, 24k Btu Series

- 9 -

LGE Internal Use Only

- 10 -

LGE Internal Use Only

Outdoor Unit

Dimensions

W

L7 L6 L8 L9

D

L1

L2

L3

L10L11

L4L5

H

Gas side

Liquid side

MODEL

18k, 24k Btu Series

DIM unit

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

- 11 -

LGE Internal Use Only

Product Specifications

Table-1

Product Specifications

Model Name

Item Unit

W

MIN kcal/h.(W)

Btu/h.

W

Cooling Capacity Type kcal/h.(W)

Btu/h.

W

Max kcal/h.(W)

Btu/h.

W

MIN kcal/h.(W)

Btu/h.

W

Heating Capacity Type kcal/h.(W)

Btu/h.

W

Max kcal/h.(W)

Btu/h.

Power Input Cooling W

Heating W

Running Current Cooling A

Heating A

Starting Current Cooling A

Heating

A

EER

Btu/h.W

COP

W/W

W/W Power Supply Ø,V,Hz Power Factor % Air Circulation Indoor,Max m3/min(CFM)

Outdoor,Max m3/min(CFM) Moisture Removal l/h.(pts/h.) Noise Level Indoor,High dB(A) 3 (Sound Med. dB(A) 3 Pressure,1m) Low dB(A) 3

Outdoor,Max dB(A) 3 Refrigerant(R410A)Charge Power Cord AWG#:P*mm

2

Connecting Cable AWG#:P*mm

2

Connecting Tube Liquid Side mm(in) (Ø. Socket Flare) Gas Side mm(in)

Length,std m(in) Drain Hose (O.D , I.D) mm(in)

Indoor mm Dimension inch (W*H*D) Outdoor mm

inch

Net Weight Indoor kg(lbs)

Outdoor kg(lbs)

AS-W1863_ Series AS-W2463_ Series

1,612 1,386 5,500 5,274 4,536

18,000

5,831

5,015

19,900

1,670 1,436 5,700 6,065 5,216

20,700

6,739 5,796

23,000

4,430 3,810 15,120 7,032 6,048

24,000

7,735

6,653

26,400

4,190 3,604 14,300 7,946 6,834

27,120

8,351 7,182

28,500 1,630 2,600 1,890 2,800

7.5 11.5

8.5 12.5

7.5 11.5

8.5 12.5

3.24 2.71

11.04 9.23

3.21 2.84

1,220-240,50 1,220-240,50

96 98

14.15(499) 16.64(587) 42(1483) 45(1587)

2.4(5.1) 2.4(5.1)

43/43 45/45 40/40 41/41 37/37 36/37 56/57 56/57

1200(42.3) 1490(52.6)

16:3*2.5 16:3*2.5 16:4*2.5 16:4*2.5

6.35(1/4) 9.52(3/8)

12.7(1/2) 15.88(5/8)

7.5(295) 7.5(295)

21.5,16.0(0.85,0.63) 21.5,16.0(0.85,0.63) 1170*315*173

46.1*12.4*6.8 870*655*320

34.3*25.8*12.6

13(28.7)

60(132.3)

1170*315*173

46.1*12.4*6.8 870*655*320

34.3*25.8*12.6

13(28.7)

60(132.3)

- 12 -

LGE Internal Use Only

Buyer Models

Item Unit

Cooling Capacity Min W

kcal/h

Btu/h

Rating W

kcal/h

Btu/h

Max W

kcal/h

Btu/h

Heating Capacity Min W

kcal/h

Btu/h

Rating W

kcal/h

Btu/h

Max W

kcal/h

Btu/h

Power Input Cooling W

Heating W

Running Current Cooling A

Heating A

Starting Current Cooling A

Heating A

EER W/W

Btu/h.W COP W/W Power Supply Ø,V,Hz Air Circulation Indoor,Max m3/min (l/s)

Outdoor,Max m3/min (l/s) Moisture Removal l/h (pts/h) Noise Level Indoor,High dB(A)±3 (Sound Low dB(A)±3 Pressure,1m) Outdoor,Max dB(A)±3 Refrigerant (R410A) Charge g (oz) Power Cord P*mm

2

Connecting Cable P*mm

2

Connecting Tube Liquid Side mm (in) (Ø. Socket Flare) Gas Side mm (in)

Length,std m (in) Dimension Indoor mm (W*H*D) in.

Outdoor mm

in.

Net Weight Indoor kg (lbs)

Outdoor kg (lbs) Energy Labeling Capacity Cooling

Heating

Energy Consumption Cooling

Heating

Star Rating Cooling

Heating

Tool (IN/OUT)

1,612 1,386 5,497 5,260 4,520

17,937

5,831 5,015

19,884

1,670 1,436 5,695 6,000 5,156

20,460

6,739 5,796

22,980

1,690 2,050

7.5

8.5

7.5

8.5

3.11

10.61

2.93

1,220-240,50

14.1 (235) 42 (700)

2.4 (5.1)

41 35 54

1,200 (42.3)

3*2.5 (20A)

4*1.5

6.35 (1/4)

12.7 (1/2)

7.5 (295)

1170*315*173

46*12.4*6.8

870*655*320

34.3*25.8*12.6 13 (28.7)

60 (132.3)

5.26

6.00

1.69

2.05

4.0

3.0

S3+UE

AS-W1863RH1

Table-2

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

CAUTION: Install the indoor unit on the wall where the height from the floor is more than 2 meters.

More than 10cm More than 10cm

More than 60cm

More than 70cm

- 13 -

LGE Internal Use Only

- 14 -

LGE Internal Use Only

Installation

Piping Length and Elevation

18k 1/2" 1/4" 4 or 5 7 15 20

24k 5/8" 3/8" 4 or 5 7 15 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 piping length is more than 5m

CAUTION: 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.

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

(S3)

Right rear piping

B

A

D

C

Installation plate

ABCD

S3

58 3 292 3

(18k~24k)

CHASSIS

(Grade)

Distance (mm)

- 15 -

LGE Internal Use Only

Installation

• 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

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"

- 16 -

LGE Internal Use Only

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

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 connection 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.

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.

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

- 17 -

LGE Internal Use Only

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. 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

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

Vinyl tape(narrow)

Adhesive

Drain pipe

Indoor unit drain hose

Plastic bands

Insulation material

Wrap with vinyl tape

Drain hose

Pipe

Vinyl tape(wide)

Vinyl tape(narrow)

Connection pipe

Connecting cable

Vinyl tape (wide)

Wrap with vinyl tape

Indoor unit pipe

Pipe

- 18 -

LGE Internal Use Only

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

- 19 -

LGE Internal Use Only

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.

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.

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

Tubing holder

- 20 -

LGE Internal Use Only

Installation

CAUTION: 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.

- 21 -

LGE Internal Use Only

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

- 22 -

LGE Internal Use Only

Installation

Indoor

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.)

Connecting the Cables

CAUTION:

• 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.

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

CAUTION:

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

Circuit Breaker Use a circuit breake or time delay fuse.

18k 24k

2.5 2.5

Unit(A) Indoor Indoor

Cable Type(B)

H05VV-F H05VV-F

NORMAL CROSS

-SECTIONAL AREA

Grade

(mm2)

18k 24k

2.5 2.5

Cable Type(B)

H07RN-F H07RN-F

NORMAL

CROSS

-SECTIONAL AREA

Grade

(mm2)

- 23 -

LGE Internal Use Only

Installation

Outdoor

1. Remove the control cover from the unit by loosening the screw. Connect the wires to the terminals on the control board individually.

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

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

4. Use a recognized circuit breaker 20A(12k) 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

Outdoor Unit

18k

20

24k

30

Circuit

Breaker

(A)

Grade

CAUTION: According to 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.

7. Always install an earth leakage circuit breaker in a wet or moist area.

8. The following would be caused by voltage drop.

• Vibration of a magnetic switch, which will damage the contact point, fuse breaking, disturbance of the normal function

of the overload.

9. The means for disconnection from a power supply shall be incorporated in the fixed wiring and have an air gap contact separation of at least 3mm in each active(p

hase) conductors.

- 24 -

LGE Internal Use Only

Installation

Checking the Drainage

To check the drainage.

1. Pour a glass of water on the evaporator.

2. Ensure the water flows through the drain hose of the indoor unit without any leakage and goes out the drain exit.

Drain piping

1. The drain hose should point downward for easy drain flow.

2. Do not make drain piping like the following.

Drain pan

Drain

hose

Leakage checking

Connecting area

drain hose

Leakage

checking

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

- 25 -

LGE Internal Use Only

Installation

Forming 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.

1. Tape the piping, drain hose and connecting cable from down to up.

2. 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.

1. Tape the piping and connecting cable from down to up.

2. Secure the taped piping along the exterior wall. Form a trap to prevent water entering the room.

3. Fix the piping onto the wall by saddle or equivalent.

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

LG AS-W1863 Series, AS-W2463 Series Svc Manual

Specifications and Main Features

Frequently Asked Questions

User Manual