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)

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

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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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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.

■ 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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LGE Internal Use Only

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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LGE Internal Use Only

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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LGE Internal Use Only

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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LGE Internal Use Only

■ 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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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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LGE Internal Use Only

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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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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LGE Internal Use Only

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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LGE Internal Use Only

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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LGE Internal Use Only

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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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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LGE Internal Use Only

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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LGE Internal Use Only

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

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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LGE Internal Use Only

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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LGE Internal Use Only

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

- 19 -

LGE Internal Use Only

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

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

- 20 -

LGE Internal Use Only

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

- 21 -

LGE Internal Use Only

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

- 22 -

LGE Internal Use Only

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

- 23 -

LGE Internal Use Only

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

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 -

LGE Internal Use Only

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