Lg Lau186hv Owner's Manual

LG Room Air Conditioner
SVC MANUAL(Exploded View)
MODELS : LS090CP(AS-C0914DH0) LS120CP(AS-C121E1H0) LS180CP(AS-C1835DM0) LS240CP(AS-C2435DM0) LS090HP(AS-H091E1H0) LS120HP(AS-H121E1H0) LS180HP(AS-H1835DM0) LS240HP(AS-H2435DM0)
Before Servicing the unit, read the safety precautions in General SVC manual. Only for authorized service personnel.
Internal Use Only
http://biz.lgservice.com
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Copyright ©2007 LG Electronics. Inc. All right reserved. Only for training and service purposes
LGE Internal Use Only
Air Conditioner Service Manual
TABLE OF CONTENTS
Safety Precautions..........................................................................................................................................3
Dimensions......................................................................................................................................................9
Symbols Used in this Manual.....................................................................................................................9
Indoor Unit..................................................................................................................................................9
Outdoor Unit.............................................................................................................................................11
Installation.....................................................................................................................................................14
Selection of the Best Location..................................................................................................................17
Piping Length and Elevation.....................................................................................................................18
How to Fix Installation Plate.....................................................................................................................19
Drill a Hole in the Wall..............................................................................................................................19
Drain hose junction...................................................................................................................................19
Flaring work and connection of piping.......................................................................................................20
Flaring work..............................................................................................................................................20
Connection of Piping Indoor.....................................................................................................................21
Connection of the Pipes-Outdoor.............................................................................................................26
Connecting the cable between indoor unit and outdoor unit...................................................................27
Connect the Cable....................................................................................................................................27
Checking the drainage and forming the pipings........................................................................................29
Checking the Drainage.............................................................................................................................29
Form the Piping........................................................................................................................................30
AIR PURGING................................................................................................................................................31
Air purging................................................................................................................................................31
Air purging with vacuum pump.................................................................................................................31
Test Running.................................................................................................................................................34
Operation.......................................................................................................................................................35
Function of Controls.................................................................................................................................35
Display Function ......................................................................................................................................39
Self-diagnosis Function............................................................................................................................39
Remote Control Operations......................................................................................................................40
Disassembly..................................................................................................................................................41
Indoor Unit................................................................................................................................................41
Troubleshooting Guide.................................................................................................................................44
Refrigeration Cycle Diagram....................................................................................................................44
2-way, 3-way Valve .................................................................................................................................45
Cycle Parts...............................................................................................................................................51
Electronic Parts........................................................................................................................................52
Schematic Diagram.......................................................................................................................................62
Electric Control Device.............................................................................................................................62
Wiring Diagram.........................................................................................................................................65
Components Location ..............................................................................................................................67
Product Specifications.................................................................................................................................72
Exploded View...............................................................................................................................................74
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Copyright ©2007 LG Electronics. Inc. All right reserved. Only for training and service purposes
LGE Internal Use Only
Safety Precautions
Safety Precautions
To prevent injury to the user or other people and property damage, the following instructions must be followed.
Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications.
Meanings of symbols used in this manual are as shown below.
This symbol indicates the possibility of death or serious injury. This symbol indicates the possibility of injury or damage to properties only.
Be sure not to do.
Be sure to follow the instruction.
Installation
Do not use damaged power cords, plugs, or a loose socket.
• There is risk of fire or electric shock.
For electrical work, contact the dealer, seller, a qualified electri­cian, or an Authorized Service Center.
• There is risk of fire or electric shock.
Always use the power plug and socket with the ground terminal.
• There is risk of electric shock.
Install the panel and the cover of control box securely.
• There is risk of fire or electric shock.
Do not modify or extend the power cord.
• There is risk of fire or electric shock.
Do not install, remove, or re­install the unit by yourself (cus­tomer).
• There is risk of fire, electric shock, explosion or injury.
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Copyright ©2007 LG Electronics. Inc. All right reserved. Only for training and service purposes
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Safety Precautions
Operation
Be cautious when unpacking and installing the product.
• Shape edges could cause injury. Be especially careful of the sharp edges.
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.
Install the indoor unit on the wall where the height from the floors more then 8ft(2.4m)
• There are sharp moving parts that could cause personal injury.
Do not handle the pipe by your­self(customer)
• High-Pressure refrigent may cause personal injury.
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.
Do not allow water to run into electric part.
• There is risk of fire, failure of the product, and/or electric shock.
8ft(2.4m)
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Copyright ©2007 LG Electronics. Inc. All right reserved. Only for training and service purposes
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Safety Precautions
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 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.
Do not store of use flammable gas or combustibles near the air conditioner.
• There is risk of fire or product fail­ure.
Do not use the product in a tightly closed space for a long time.
• Oxygen deficiency could occur.
• Some ventilation by opeing win­dow is necessary for the fresh air.
When flammable gas leaks, turn off the gas and open a window for venti­lation before turning the product on. Do not use the telephone or turn switches on or off.
• There is risk of explosion or fire.
Unplug the unit if strange sounds odors or smoke comes from it.
There is risk of fireproduct failure and/or electric shock.
Stop operation and close any window in storm or hurricane. before the hurricane arrives.
• There is risk of property damage, failure of product, 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.
When the product is soaked (flooded or submerged), contact an Authorized Service Center.
• There is risk of electrical shock.
Thinner
Wax
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Copyright ©2007 LG Electronics. Inc. All right reserved. Only for training and service purposes
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Safety Precautions
Ventilate the product from time to time when operating it togeth­er with a stove, etc.
• There is risk of fire or electrical shock.
Unplug the appliance before performing cleaning or mainte­nance.
• There is risk of electric shock.
When the product is not be used for a long time disconnect the power supply plug or turn off the breaker.
• There is risk of product damage or failure, or unintended opera­tion.
Take care to ensure that nobody could step on or fall onto the outdoor unit.
• There could result in personal injury and product damage.
Do not insert hands or other objects through the air inlet or outlet while the air conditioner is plugged in.
• There are sharp and moving parts that could cause personal injury.
Always check for gas(refriger­ant) leakage after installation or repair of product.
• Low refrigerant levels may cause product failure.
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.
Do not install the product where the noise or hot air from the out­door unit could damage the neighborhoods.
• It may cause a problem for your neighbors.
Installation
90˚
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Copyright ©2007 LG Electronics. Inc. All right reserved. Only for training and service purposes
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Operation
Safety Precautions
Use two or more people to lift and transport the air conditioner
• Avoid personal injury.
Do not install the product where it will be exposed to sea wind (salt spray) directly.
• It may cause corrosion in the product. Corrosion, particularly on the condenser and evaporator fins, could cause product mal­function or inefficient operation.
Do not direct airflow at room occupants.
• This could damage your health.
Do not use the product for special purposes, such as preserving foods, works of art, etc. It is a consumer air conditioner, not a precision refrigeration system.
• There is risk of damage or loss of property.
Do not block the inlet or outlet of air flow.
• It may cause product failure.
Use a soft cloth to clean. Do not use harsh detergents, solvents, etc.
• There is risk of fire, electric shock or damage to the plastic parts of the product.
Do not touch the metal parts of the product when removing the air filter. They are very sharp!
• There is risk of personal injury.
Do not step on or put anything on the product. (outdoor unit)
• There is risk of personal injury and failure of product.
Always insert the filter securely. Clean the filter every two weeks or more often if necessary.
• A dirty filter reduces the efficien­cy of the air conditioner and
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Copyright ©2007 LG Electronics. Inc. All right reserved. Only for training and service purposes
LGE Internal Use Only
Dimensions
Do not drink the water drained from the unit.
• It is not sanitary and could cause serious health issues.
Use a firm stool or ladder when cleaning or maintaining the air conditioner.
• Be careful and avoid personal injury.
Replace all the batteries in the remote.
• There is risk of fire or explosion.
Do not recharge or disassemble the batteries. Do not dispose of batteries in a fire.
• They may burn or explode.
If the liquid from the batteries gets onto your skin or clothes, wash it well with clean water. Do not use the remote if the batteries have leaked.
• The chemicals in batteries could cause burns or other health hazards.
Disuse
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Copyright ©2007 LG Electronics. Inc. All right reserved. Only for training and service purposes
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Dimensions
Dimensions
D
H
W
Installation plate
W mm(inch) 840(33.1) 894(35.2) 894(35.2)
H mm(inch) 270(10.6) 295(11.6) 295(11.6) D mm(inch) 153(6.0) 165(6.5) 165(6.5)
Model
Dimension
9 Btu Series
(C/O)
9 Btu Series
(H/P)
12
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
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Copyright ©2007 LG Electronics. Inc. All right reserved. Only for training and service purposes
LGE Internal Use Only
D
H
W
Installation plate
Dimensions
W mm(inch) 1090(42.9) 1090(42.9)
H mm(inch) 300(11.8) 300(11.8) D mm(inch) 178(7.0) 178(7.0)
Model
Dimension
18 Btu Series 24 Btu Series
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Dimensions
Outdoor Unit
1. 9k, 12k
W
L2
L3
L1
D
H
L4
L5
Gas side
(3-way valve)
Liquid side
(2-way valve)
MODEL
9k, 12k
DIM unit
W mm(inch) 770(30.3)
H mm(inch) 540(21.3)
D mm(inch) 245(9.6) L1 mm(inch) 287(11.3) L2 mm(inch) 64(2.5) L3 mm(inch) 518(20.4) L4 mm(inch) 10(0.4) L5 mm(inch) 100(3.9)
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Copyright ©2007 LG Electronics. Inc. All right reserved. Only for training and service purposes
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Dimensions
2. 18k, 24k
W
L6 L5 L7 L8
D
L1
L2
L9L10
L3L4
H
MODEL
18k, 24k
DIM
W mm(inch) 870(34.3)
H mm(inch) 655(25.8)
D mm(inch) 320(12.6) L1 mm(inch) 370(14.6) L2 mm(inch) 25(1.0) L3 mm(inch) 630(24.8) L4 mm(inch) 25(1.0) L5 mm(inch) 546(21.5) L6 mm(inch) 162(6.4) L7 mm(inch) 162(6.4) L8 mm(inch) 54(2.1) L9 mm(inch) 74.5(2.9)
L10 mm(inch) 79(3.1)
Introduction
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Introduction
This symbol alerts you to the risk of electric shock.
This symbol alerts you to hazards that may cause harm to the air condi­tioner.
This symbol indicates special notes.
Symbols Used In This Manual
Features
Air Intake Vents
Air Outlet Vents
Connecting Wires
Piping Drain Hose
Base Plate
Air Outlet Vents
Air Intake Vents
Piping
Connecting Wires
Drain Hose
Signal Receptor
Base Plate
Front Panel
Air Inlet
Air Filter
NOTICE
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Copyright ©2007 LG Electronics. Inc. All right reserved. Only for training and service purposes
LGE Internal Use Only
Installation
Type "A" screw and plastic anchor
Type "B" screw
Remote Control Holder
Installation plate
Figure FigureName
Screw driver
Electric Drill
Measuring Tape, Knife
Hole Core Drill
Spanner
Torque wrench
Ohmmeter
Hexagonal wrench
Ammeter
Gas Leak Detector
Thermometer,
Level
Flaring Tool Set
Name
Installation Parts
Installation Tools
Read carefully, and then follow step by step.
Installation
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Installation
Installation Map
Installation parts you should purchase.
Vertical Air deflector
Air Discarge
Forced Operation Button
Operation Indication Lamps/
Signal Receptor
Vinyl tape(Wide)
Apply after carrying out a drainage test.
To carry out the drainage test, remove the air filters and pour water into the heat exchanger.
Saddle
Gas side piping Liquid side piping Additional drain pipe
Drain Hose
Base Plate
Air Inlet Vents
Connecting cable
Installation Plate Sleeve Bushing-Sleeve
Putty(Gum Type Sealer)
Bend the pipe as closely on the wall as possible, but be careful that it doesn't break.
NOTICE
NOTE: refrigerant line wall thickness must be at least 0.8 mm (0.031 inch)
Air Outlet Vents
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1. Check the quality label on the indoor and outdoor unit.
2. Make certain that the refrigerant is R-410A.
THIS PRODUCT CONTAINS R-410A REFRIGERANT
1) Different compressor oil
- R-410A(Polyol ester) / R-22(Mineral).
- Do not mix the existing mineral oil.
- Do not apply used pipe, tools and gauges covered with the existing mineral oil.
2) Absorption of moisture
-Compressor’s oil has the high absorption rate of moisture.
3) Composition
- R-410A(R32:R125=50:50wt%). NOTE: Never mix with other refrigerants
4) High pressure.
- 1.6 times higher than R-22.
- High Pressure refrigerant may cause personal injury.
Do not handle the pipe by yourself (customer) High-pressure refrigerant may cause personal injury.
- manifold gauge ,charging and any piping tools must be dedicated to R-410A systems.
Confirm The Refrigerant
Boiling Pt.(
°C) Vapor pressure(25°C)(kg f/cnf) V apor density(25°C)(kg/m
2
)
R-410A -51.4 15.9 64 R-22 -40.8 9.6 44.4
Installation
NOTICE
Example : Split type 12,000 Btu/h
120
100
100
80
93
89
84
76
60
40
20
0 R-410A R-22
100%
70% 50% 30%
0%
100%70%50%30%0%
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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(3.9in). The front of the unit should have more than 70cm(27.6in) of space.
3. Do not place animals and plants in the path of the warm air.
4. Take the air conditioner weight into account and select a place where noise and vibration are minimum.
5. 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.
If the outdoor unit is installed on roof structures or walls, this may result in excessive noise and vibra­tion, and may be also classed as non serviceable 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 space around the left and right of the unit is more than 30cm(11.8in). The unit should be installed as high on the wall as possi­ble, allowing a minimum of 12cm(4.7in) from ceiling.
6. Use a stud finder to locate studs to prevent unnecessary damage to the wall.
Select The Best Location
Install the indoor unit on the wall where the height from the floors more than 2.3meters(7.6ft). A minimum pipe run of 7.5meters(24.6ft) is required to minimize vibration and excessive noise.
More than
12cm(4.7in)
More than
30cm(11.8in)
More than
30cm(11.8in)
More than 8ft(2.4m)
More than
10cm(3.9in)
More than
10cm(3.9in)
More than 60cm(23.6in)
More than
60cm(23.6in)
More than
70cm(27.6in)
Installation
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Piping Length And Elevation
• Capacity is based on standard length and maximum allowance length is on the basis of reliability.
• Oil trap should be installed every 5~7meters (16.4~23.0ft).
Pipe Size
Capacity
(Btu/h)
Suction
Evap
Max.
length
A m(ft)
Additional Refrigerant
g/m(oz/ft)
Max.
Elevation
B m(ft)
Standard
Length
m(ft)
In case more than 5m(16.4ft)
Outdoor unit
Indoor unit
A
B
A
Oil trap
Outdoor unit
Indoor unit
B
9k(C/O) 3/8" 1/4" 7.5(25) 7.5(25) 15(49) 20(0.22)
9k(H/P), 12k 1/2" 1/4" 7.5(25) 7.5(25) 15(49) 20(0.22)
18k(C/O) 1/2" 1/4" 7.5(25) 15(49) 30(98) 20(0.22)
18k(H/P), 24k 5/8" 1/4" 7.5(25) 15(49) 30(98) 30(0.32)
Installation
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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.
How To Mount Installation Plate
Chassis
Hook
Installation Plate
Type A
• Drill the piping hole with a ø70mm(2.76in) hole
core drill. Drill the piping hole at either the right or the left with the hole slightly slanted to the out­door side.
Drill a Hole In The Wall
5-7mm
(0.2~0.3")
Indoor
WALL
Outdoor
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.
Installation plate
Left rear piping Right rear piping
Ø70mm
Ø70mm
D
B
A
C
ABCD S4 50 105 59 105 SE 65 110 85 110 S5 95 122 235 122
CHASSIS
(Grade)
Distance (mm)
Installation
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Flaring Work
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(59.1in) 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
• Carry out flaring work using flaring tool as shown below.
Main cause for gas leakage is due to defect in flaring work. Carry out correct flaring work in the follow­ing procedure.
mm inch mm inch Ø6.35 1/4 0~0.5 0~0.020 Ø9.52 3/8 0~0.5 0~0.020 Ø12.7 1/2 0~0.5 0~0.020
Ø15.88 5/8 0~1.0 0~0.039
Outside diameter A
Bar
Copper pipe
Clamp handle
Red arrow mark
Cone
Yoke
Handle
Bar
"A"
Pipe
Reamer
Point down
Copper
pipe
90°
Slanted Uneven Rough
Firmly hold copper pipe in a die in the dimen­sion shown in the table abov e .
Flare nut
Copper tube
Installation
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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.
Route the indoor tubing and the drain hose in the direction of rear left.
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 con-
nection 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.
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 recom-
mended.
Indoor unit installation
• Hook the indoor unit onto the upper portion of
the installation plate.(Engage the three hooks of the rear top and rear lower of the indoor unit with the upper edge and lower edge of the installation plate.) Ensure that the hooks are properly seated on the installation plate by moving it left and right.
Connecting The Piping
For left rear piping
Installation
NOTICE
1 2
Connecting
cable
Drain pipe
Indoor unit
Spacer
Installation plate
8cm
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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.
Route the indoor tubing and the drain hose to the required piping hole position.
Plastic bands
Insulation material
Connection pipe
Flare nut
Indoor unit tubing
Torque wrench
Spanner (fixed)
Vinyl tape(narrow)
Adhesive
Drain pipe
Indoor unit drain hose
• When extending the drain hose at the indoor unit, install the drain pipe.
• Tighten the flare nut with a wrench.
For right rear piping
Connecting the pipings to the indoor unit and drain hose to drain pipe.
• Put a couple drops of refrigerant oil on the face of the flare before assembling taking care not to add any contaminants.
• Align the center of the pipings and sufficiently tighten the flare nut by hand.
Indoor unit tubing Flare nut Pipings
Drain hose
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
mm inch
Torque
Vinyl tape(narrow)
Connection pipe
Connecting cable
Vinyl tape (wide)
Wrap with vinyl tape
Indoor unit pipe
Pipe
• Bundle the piping and drain hose together by wrapping them with vinyl tape over the range within which they fit into the rear piping housing section.
Wrap with vinyl tape
Drain hose
Pipe
Vinyl tape(wide)
• Wrap the area which accommodates the rear piping housing section with vinyl tape.
• Mount the clamp on the boss with a type "B" screw.(SE-H/P: 9k, 12k C/O: 12k)
Installation
Type "B" screw
Clamp
Boss
Drain hose
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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.
Tape the drain hose and the connecting cable.
• Connecting cable
Connecting the pipings to the indoor unit and the drain hose to drain pipe.
• Put a couple drops of refrigerant oil on the face of the flare before assembling taking care not to add any contaminants
• Align the center of the pipings and sufficiently tighten the flare nut by hand.
• Tighten the flare nut with a wrench.
Indoor unit tubing Flare nut Pipings
Torque wrench
Indoor unit tubing
Spanner (fixed)
Connection pipe
Flare nut
Indoor unit installation
• Hook the indoor unit onto the upper portion of
the installation plate.(Engage the three hooks of the rear top and rear lower of the indoor unit with the upper edge and lower edge of the installation plate.) Ensure that the hooks are properly seated on the installation plate by moving it left and right.
Vinyl tape
Adhesive
Drain hose
Indoor unit drain hose
(narrow)
• When extending the drain hose at the indoor unit, install the drain pipe.
Connecting pipe
Connecting cable
Tape
Drain hose
Drain hose
Connecting
cable
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
• Mount the clamp on the boss with a type "B"
screw.(SE-H/P: 9k, 12k C/O: 12k)
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.
Plastic bands
Insulation material
Installation
Type "B" screw
Clamp
Boss
Drain hose
- 24 -
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Reroute the pipings and the drain hose across the back of the chassis.
Reroute the pipings and the drain hose across the back of the chassis.
Drain hose
Vinyl tape(narrow)
Pipe
Wrap with vinyl tape(wide)
• 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.
Piping for passage through piping hole
Drain hose
Connecting
cable
• Wrap the area which accommodates the rear piping housing section with vinyl tape.
Vinyl tape(narrow)
Connection pipe
Connecting cable
Indoor unit piping
Pipe
Vinyl tape (wide)
Wrap with vinyl tape
Installation
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