LG LP090CED-HED, LP120HED, LP120CED-HED, LP150CED-HE Schematic

http://www.lgservice.com

LG

LG Packaged Terminal

Air Conditioner/Heat Pump

SERVICE MANUAL

CAUTION

•BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

•FOR AUTHORIZED SERVICE ONLY.

CONTENTS

1. PREFACE
1.1 SPECIFICATIONS ..........................................	3
1.2 FEATURES AND BENEFITS..........................	4
1.3 CONTROL LOCATIONS .................................	6
1.4 ADDITIONAL CONTROLS..............................	8
2. DISASSEMBLY INSTRUCTIONS
2.1 MECHANICAL PARTS..................................	10
2.1.1 FRONT GRILLE ...................................	10
2.1.2 CONTROL BOX ...................................	11
2.2 AIR HANDLING PARTS................................	12
2.2.1 ELECTRIC HEATER
(Electric heater model only) .................	11
2.2.2 CROSS FLOW FAN.............................	12
2.2.3 AXIAL FAN...........................................	13
2.2.4 SHROUD..............................................	13
2.3 ELECTRICAL PARTS ...................................	14
2.3.1 OUTDOOR MOTOR ............................	14
2.3.2 INDOOR MOTOR ................................	14
2.3.3 COMPRESSOR ...................................	14
2.3.4 CAPACITOR ........................................	14
2.3.5 POWER CORD ....................................	14
2.3.6 P.C.B....................................................	15
2.4 REFRIGERATION CYCLE............................	15
2.4.1 CONDENSER ......................................	16

2.4.2 EVAPORATOR ....................................	16
2.4.3 CAPILLARY TUBE...............................	16
3. INSTALLATION
3.1 HOW TO INSTALL THE UNIT ......................	17
3.2 SUGGESTED TOOL REQUIREMENTS .......	19
3.2.1 PREPARATION OF SLEEVE ..............	20
3.2.2 PREPARATION OF THE FRONT
GRILLE ................................................	20
3.2.3 UNIT INSTALLATION ..........................	21
3.3 ELECTRICAL REQUIREMENTS ..................	22
3.3.1 ELECTRICAL DATA (FOR 230V/208 MODEL)........	22
3.3.2 ELECTRICAL SAFETY ............................	22
4. FIELD INSTALLED ACCESSORIES...	23
5. FERFORMANCE DATA.................................	39
6. TROUBLESHOOTING GUIDE
6.1 OUTSIDE DIMENSIONS...............................	44
6.2 PIPING SYSTEM ..........................................	44
6.3 TROUBLESHOOTING GUIDE......................	45
7. SCHEMATIC DIAGRAM .....................	50
8. EXPLODED VIEW..................................	52
9. REPLACEMENT PARTS LIST .......	53

1. PREFACE

This SERVICE MANUAL provides various service information, including the mechanical and electrical parts, etc. This room air conditioner was manufactured and assembled under a strict quality control system. The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.

—2—

1.1 SPECIFICATIONS

Cooling/Electric Heater

	Model Name	Cooling (Btu/h)	Cooling Watts (W)	EER	Electric Heat	Rated Amp,	Mini Circuit
						Cooling	Protection (Amps)
	LP070CEM	7,600/7,400	600/580	12.7/12.7	2.5kW E/Heater	2.7/2.9	20
	LP090CEM	9,000/8,800	770/750	11.7/11.7	3.5kW E/Heater	3.5/3.8	20
	LP120CEM	11,800/11,500	1,055/1,025	11.2/11.2	3.5kW E/Heater	4.8/5.2	20
	LP150CEM	14,300/14,100	1,430/1,410	10.0/10.0	3.5kW E/Heater	6.5/7.1	20
	LP070CED	7,600/7,400	600/580	12.7/12.7	2.5kW E/Heater	2.7/2.9	20
	LP090CED	9,000/8,800	770/750	11.7/11.7	3.5kW E/Heater	3.5/3.8	20
	LP120CED	11,800/11,500	1,055/1,025	11.2/11.2	3.5kW E/Heater	4.8/5.2	20
	LP150CED	14,300/14,100	1,430/1,410	10.0/10.0	3.5kW E/Heater	6.5/7.1	20

Cooling/Heat Pump/Electric

Model Name	Cooling	Cooling	EER	Reverse	COP	Electric Heat	Rated Watts,	Rated Amp,	Rated Amp,	Mini Circuit
	(Btu/h)	Watts (W)		Cycle (Btu/h)			Heating	Cooling	Heating	Protection (Amps)
LP070HEM	7,600/7,300	600/575	12.7/12.7	6,400/6,200	3.5/3.5	2.5kW E/Heater	535/520	2.7/2.9	2.4/2.6	20
LP090HEM	9,100/8,900	775/760	11.7/11.7	8,200/8,000	3.4/3.4	3.5kW E/Heater	705/690	3.7/3.9	3.2/3.5	20
LP120HEM	12,100/11,800	1,090/1,065	11.1/11.1	10,900/10,700	3.3/3.3	3.5kW E/Heater	970/950	5.0/5.4	4.4/4.8	20
LP150HEM	14,300/14,100	1,460/1,440	9.8/9.8	13,500/13,300	3.1/3.1	3.5kW E/Heater	1,275/1,255	6.7/7.3	5.8/6.3	20
LP070HED	7,600/7,300	600/575	12.7/12.7	6,400/6,200	3.5/3.5	2.5kW E/Heater	535/520	2.7/2.9	2.4/2.6	20
LP090HED	9,100/8,900	775/760	11.7/11.7	8,200/8,000	3.4/3.4	3.5kW E/Heater	705/690	3.7/3.9	3.2/3.5	20
LP120HED	12,100/11,800	1,090/1,065	11.1/11.1	10,900/10,700	3.3/3.3	3.5kW E/Heater	970/950	5.0/5.4	4.4/4.8	20
LP150HED	14,300/14,100	1,460/1,440	9.8/9.8	13,500/13,300	3.1/3.1	3.5kW E/Heater	1,275/1,255	6.5/7.3	5.8/6.3	20

LP 12 0 C M 2

12	34	5	6	7	8
Digits 1,2			- LG Packaged Terminal Air Conditioner				Digit 6	- Product Type
Digits 3,4			- Unit Cooling Capacity					C = Air Conditoner
			07	=	7,000 Btu/h			H = Heat Pump
			09	=	9,000	Btu/h	Digit 7- Electric Heat
			12	= 12,000		Btu/h		E = Electric Heater
			15	= 15,000		Btu/h	Digit 8	- Electric Type
								D = Manual Control
								M = Electronic Control

—3—

1.2 FEATURES AND BENEFITS

The PTAC has many features, some of which are different than those found on conventional PTAC units. The servicer must be familiar with these features in order to properly service the unit.

THE SLEEVE AND THE REAR GRILLE

(Available as an option)

VERTICAL AIR DEFLECTOR	SLEEVE ASSEMBLY	REAR GRILLE
(Horizontal Louver)	(Including Aluminum Rear Grille)	(Aluminum Rear Grille)

AIR FILTER

R

O

O

D

N

I

INLET GRILLE

(Air Intake)

EXPANDED METAL GRILLE (Superior for a performance)

•IIR (Infinite Impulse Response)

The IIR function senses the temperature several times per second and makes micro-adjustments several times per

•Compressor Restart Delay

This feature extends the overall life of compressor by preventing the short-cycling of the air-conditioner. When the compressor restarts, LG PTAC is designed to give a minimum of three minutes to have a time of equalizing the refrigerant pressures for optimizing cycling.

•Fan-Only Setting - High/Low

The fan can run at HIGH or LOW speed without COOLING or HEATING to provide air circulation and ventilation.

•Indoor Fan Speed Selections - High/Low

The fan can run at HIGH or LOW speed for either COOLING or HEATING.

•Two Fan motors

The unit has two fan motors to provide quiet operation and maximum efficiency.

•LED Diagnostics

All units have this feature indicating the problem when the unit is not operating properly with easy-to-read diagnostics. For example, 1 blink every 2 seconds indicates compressor failure.

—4—

•Indoor Filters

The unit uses two indoor filters which slide in and cut easily. The filters may be cleaned by washing and brushing without removing the front grille.

•Rotary Compressor

The unit uses a rotary compressor for quiet, reliable operation and long life.

•2 Position Discharge Grille

The discharge grille can provide air flows upward at an angle of 40 off vertical or 15 degree off vertical. The angle is changed by removing the front grille and 4 screws that fasten the discharge grille to the front grille and rotating the louvers to an alternate position.

•Indoor Room Freeze Protection

When the unit senses the room temperature falls to less than 40° F the unit activates the fan motor and either the electric resistance heater or the hydronic heater to prevent pipes or fixtures from freezing. This also overrides front desk control of the unit mounted or wall mounted controls.

•Door Switch/Occupancy Sensor

The unit is capable of accommodating a field installed door switch and occupancy sensor to operate the energy management feature. For additional information, refer to the unit operation section.

•Compressor Overload Protection

This feature prevents the damage of the compressor by sensing the indoor tube temperature in heating. If the indoor temperature is over 130˚ F, the outdoor fan will be switched off and back on when the temperature drops below 120˚ F.

•Outdoor Air Temperature Switchover

This will effectively change the unit from heat pump mode to total electric resistance heat.

•Temperature limits

The unit is programmed to provide both heating and cooling temperature limits by dip switches on control panel from 50˚ F to 90˚ F. Temperature limits help to prevent overheating and overcooling and reduce energy costs.

•Condensate Drain Valve

The unit has a condensate drain valve to prevent water from collecting or freezing in the basepan.

•Quick Heater Recovery

The unit is designed to operate the electric heater to warm the room to the temperature set point as soon as heat pump cycle is on in heating. This feature has an advantage of reducing the time to reach the set point and improving the temperature increase for better comfort.

•Reverse Cycle Defrosting - (PTHDs only)

The unit will activate the reverse cycle defrost when the outdoor coil temperature has remained at a cold temperature to form the ice on the coil.This ice will reduce airflow though the coil and will also reduce the efficiency of unit. The LG PTHP will employ an active reverse cycle defrost function to melt the ice off the outdoor coil for insuring room comfort conditions and savings from extended operation.

•High Temperature Heat Pump Operation Protection

The compressor will be switched off to prevent damage when the heat pump is operated in high outdoor temperatures.

•Remote Thermostat Control

Each unit is built to be operated from any standard 4 or 5 wire remote-mounted thermostat, if desired. The unit has a built-in low voltage power source which can accommodate a large variety of thermostat choices-manual, auto changeover, or programmable. A remote thermostat can also be added to any installed unit.

•Zone Sensor

Occupants enjoy ultimate comfort with consistent climate control. Attach an optional, inexpensive remote Zone Sensor to exactly match the functions of the PTAC without disabling any features.

—5—

1.3 CONTROL LOCATIONS

• OPERATION

ELECTRIC HEATING MODEL

TEMPERATURE CONTROL

Set the Thermostat control to the desired temperature mark 5 (the mid-point is a good starting position). If the room temperature is not satisfactory after a reasonable time, adjust the control to a cooler or warmer setting, as appropriate.

• VENTILATION

The ventilation lever is located to the lower left side of the unit. The ventilation lever must be in the CLOSE position in order to maintain the best cooling conditions.

When fresh air is necessary in the room, set the ventilation lever to the OPEN position.

The damper is opened and outdoor air is drawn into the room. This will reduce the cooling or heating efficiency.

CAUTION

has performed a cooling or turned off or set to the fan

minutes before resetting to the

NOTE

A slight heat odor may come from the unit when first switching to HEAT after the cooling season is over.

This odor, caused by fine dust particles on the heater, will disappear quickly. This is harmless.

COOLING ONLY MODEL

OPERATION MODE SELECTOR

OFF	Turns air conditioner off.
LOW FAN	Low speed fan operation without cooling.
HIGH FAN	High speed fan operation without cooling.
LOW COOL	Cooling with the low speed fan operation.
HIGH COOL	Cooling with the high speed fan operation.
LOW HEAT	Heating with the low speed fan operation.
HIGH HEAT	Heating with the high speed fan operation.

VENT

VENT CLOSE

OPEN

—6—

• ELECTRONIC CONTROLS

The controls will look like one of the following.

FAN SPEED

• Every time you push this button, it cycles through the settings as follows: {High → Low → High → Low}

		HEAT
		E/SAVE
F1	LOW	FAN	HIGH
F2	HIGH
		COOL	LOW	TIMER

ON

OFF

REMOTE CONTROL SIGNAL RECEIVER

POWER

•To turn the air conditioner ON, push this button. To turn the air conditioner OFF, push the button again.

•This button takes priority over any other button.

•At initial power-up, the unit defaults to COOL mode, HIGH fan, 72˚ F.

MODE

-Push this button to cycle through the modes from COOL → FAN →HEAT→ COOL.

-COOL

•Fan runs continually for normal cooling operation.

-ENERGY SAVER

•The fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will turn on and the unit will check the room air temperature to determine if cooling is needed.

-FAN

•Fan operation without heating or cooling.

TIMER

TEMPERATURE SETTING

• Use this button to automatically control the temperature of the room.

The temperature can be set within a range of 54° F to 86° F by increments of 1° F.

• The setting appears in the display.

-SHUT-OFF TIME

•You will usually use shut-off time while you sleep.

•If unit is running, use Timer to set number of hours until shut-off.

•For your sleeping comfort, once Time is set, the Temperature setting will raise 2° F after 30 minutes, and once again after another 30 minutes.

•Push Timer to cycle through the settings from 1 Hour → 2 Hours → ... → 12 Hours maximum.

—7—

1.4 ADDITIONAL CONTROLS

• REMOVING THE FRONT GRILLE

Additional controls are available after removing the front grille and option cover of control box.

To remove the front grille, pull out the bottom of front grille and then lift up.

To replace the front grille, place the tabs over the top of the unit and push the bottom of front grille until the clips snap into place.

• ADDITIONAL CONTROLS

The additional controls are located behind the option cover of control box. The standard settings will be in the OFF position. The authorized service man has to check switches and ensure the switches are in the desired position.

REMOTE ON ON ON ON

ON

OFF

LOCAL OFF OFF OFF OFF

Remote/Local 1

2

3

4

5

Energy Saver

Temperature Limit 1

Temperature Limit 2

Temperature Limit 3

• TEMPERATURE LIMITING

Temperature Limiting can save money by limiting the lowest temperature for cooling and the highest temperature for heating. The temperature limiting is controlled by dip switches #1 - #3.

This temperature limiting is not available with the Remote Wall Thermostat.

Temperature	Temperature	Temperature			Cooling Operation			Heating Operation
Limit #1	Limit #2	Limit #3
					Lowest Temp.	Highest Temp.		Lowest Temp.	Highest Temp.
OFF	OFF	OFF			54° F (12.2° C)	86° F (30.0° C)		54° F (12.2° C)	86° F (30.0° C)
ON	OFF	OFF			56° F (13.3° C)	86° F (30.0° C)		54° F (12.2° C)	84° F (28.9° C)
OFF	ON	OFF			58° F (14.4° C)	86° F (30.0° C)		54° F (12.2° C)	82° F (27.8° C)
ON	ON	OFF			60° F (15.5° C)	86° F (30.0° C)		54° F (12.2° C)	80° F (26.7° C)
OFF	OFF	ON			62° F (16.6° C)	86° F (30.0° C)		54° F (12.2° C)	78° F (25.5° C)
ON	OFF	ON			64° F (17.7° C)	86° F (30.0° C)		54° F (12.2° C)	76° F (24.4° C)
OFF	ON	ON			66° F (18.9° C)	86° F (30.0° C)		54° F (12.2° C)	74° F (23.3° C)
ON	ON	ON			68° F (20.0° C)	86° F (30.0° C)		54° F (12.2° C)	72° F (22.2° C)
	#6				#7			Unit Type
	OFF				OFF			Cooling+Electric Heater
	OFF				ON			Cooling Only
	ON				OFF			Heat Pump Only
	ON				ON			Cooling Only+Heat Pump

—8—

• REMOTE/LOCAL CONTROL

When remote/local switch #1 is on, it allow the unit to operate by the control of Remote Wall Thermostat. The unit control by knobs are not available.

• ENERGY SAVER

The energy saver switch #2 is on. This switch is set at cycle fan to provide continuous fan operation in cool or heat modes. When the switch is off the continuous fan allows continuous circulation of room air and make the more balanced temperature of the room. When the switch is on the fan is on or off with the compressor or with the heater.

• FRONT DESK CONTROL

When the pair wire is connected to the connector LO and LI, the unit can be turned ON or OFF with a switch located at the Front Desk Control panel. When the front desk switch is ON, the fan operate according to the condition of setting without working compressor and heater. When the front desk switch is OFF, the unit can operate according to the setting of controls.

Wire # AWG	Maximum Length
#22	600 ft (180 m)
#20	900 ft (270 m)
#18	1500 ft (450 m)
#16	2000 ft (610 m)

LO LI GL GH O W Y R C

Front Desk Switch

• REMOTE WALL THERMOSTAT

When the wires are connected, the unit will be controlled by a remote wall thermostat.

The thermostat connections supply the 24 Volt AC. When you install the digital/electronic thermostat, you must set it to the 24 Volt AC. See the installation Instruction in this manual for the Remote Wall Thermostat.

24 Volt-N

24 Volt-L

Compressor

Heater

Reversing Valve

High Fan

Low Fan

Note: The following figures show wiring schematics for heat pump and straight cool units with electric heat, respectively.

Wiring Schematic for

Remote Heat Pump

Wiring Schematic for

Straight Cool Unit.

LO LI GL GH O W Y R C

—9—

2. DISASSEMBLY INSTRUCTIONS

— Before the following disassembly, POWER SWITCH is set to OFF and disconnected the power cord.

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Remove the front grille. (See Figure 1)

2. To remove the front grille, pull out the bottom of the front grille and then lift up.

Re-install the component by referring to the removal procedure.

3. To replace the front grille, place the tabs over the top of the unit and push the bottom of front grille until the clips snap into place.

• This Room Air Conditioner (PTAC) discharges air from the top of the unit through reversible, 2-position

discharge grille louvers. The unit is shipped from the 40˚ factory with the discharge grille louvers at an angle

of 40˚ off vertical. In the alternate position, the louvers will be at an angle of 15˚ off vertical.

15˚

To adjust air direction, remove the front grille. Remove the 4 screws that fasten the discharge grille to the front grille.

Flip the discharge grille 180°, then reattach the discharge grille to the front grille with 4 screws.

Screws

—10—

2.1.2 CONTROL BOX

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the two screws which fasten the control box. (See Figure 2)

3. Pull the control box from the Air guide.

Figure

4. Remove the control box cover. (See Figure 3)

5. Disconnect wire housings on the control box.

Figure 3

6. Pull the control box assembly out from the unit. (See Figure 4)

7. Re-install the components by referring to the removal procedure.

Figure 4

—11—

2.2 AIR HANDLING PARTS

2.2.1 ELECTRIC HEATER

(ELECTRIC HEATER MODEL ONLY)

1. Remove the front grille.(Refer to section 2.1.1)
2.	Remove the control box assembly.
	(Refer to section 2.1.2)
3.	Remove the 4 screws which fasten the Evaporator.	Figure 5
	(See Figure 5)

4. Remove the top cover assembly, net steel, brace. (See Figure 6)

Figure 6

5. Remove the 6 screws which fasten the Air-guide. 6. Pull the Air-guide assembly out from the unit.

(See Figure 7)

Figure 7

7. Remove the 2 screws which fasten the electric heater in the left hand side.

8. Pull the electric heater towards left for a while and then lift up vertically to disassemble it completely from Air guide.

Figure 8

—12—

2.2.2 CROSS FLOW FAN

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the control box assembly. (Refer to section 2.1.2)

3. Remove the Air-Guide Assembly from the unit. (Refer to section 2.2.1)

4. Loosen the screw on the cross flow fan. (See Figure 9)

Figure 9

5. Remove the 4 screws which fasten the indoor motor and the earth wire. (See Figure 10)

6. Remove the supports on both sides.

7. Pull the cross flow fan out from the air-guide. 8. Re-install the components by referring to the

removal procedure.

Figure 10

2.2.3 AXIAL FAN

1. Remove the brace.

2. Remove the 4 screws which fasten the condenser with the shroud and the basepan. (See Figure 11)

3. Remove the condenser sideways carefully.

Figure 11

4. Remove the clamp which secures the fan with pliers.(See Figure 12)

5. Remove the axial fan.

6. Re-install the components by referring to the removal procedure.

Figure 12

—13—

2.2.4 SHROUD

1.Remove the axial fan. (Refer to section 2.2.3)

2.Remove the 4 screws which fasten the condenser with the shroud and the basepan. (See Figure 11)

3.Remove the shroud.

4.Re-install the component by referring to the removal procedure.

2.3. ELECTRICAL PARTS

2.3.1 OUTDOOR MOTOR

1.Remove the clamp cord and disconnect a wire housing in control box. (Refer to section 2.1.2)

2.Remove the axial fan. (Refer to section 2.2.3)

3.Remove the 2 screws which fasten the motor. (See Figure 12)

4.Remove the motor

5.Re-install the component by referring to the removal procedure, above.

2.3.2INDOOR MOTOR (Refer to section 2.2.2)

2.3.3COMPRESSOR

1.Discharge the refrigerant system using a refrigerant recovery system.

If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the refrigerant. Leave the valve in place after servicing the system.

2.Disconnect the 3 leads from the compressor.

3.After purging the unit completely, unbraze the suction and discharge tubes at the compressor connections.

4.Remove the 3 nuts and the 3 washers which fasten the compressor. (See Figure 15)

5.Remove the compressor.

6.Re-instill the components by referring to the removal procedure, above.

Figure 13

Figure 14

Figure 15

2.3.4 CAPACITOR

1. Remove the control box. (Refer to section 2.1.2)

2. Remove 1 screw and disconnect the leads which connected to the box type capacitor.

(See Figure 16)

3. Remove 1 screw and the clamp which fastens the can-type capacitor.

4. Disconnect all the leads of capacitor terminals. 5. Re-install the components by referring to the

removal procedure, above.

Figure 16

—14—

2.3.5 POWER CORD

1.Remove the control box. (Refer to section 2.1.2)

2.Disconnect the grounding screw from the control box.

3.Disconnect 2 receptacles.

4.Remove a screw which fastens the clip cord.

5.Separate the power cord from the control box. (See Figure 17)

6.Re-install the component by referring to the removal procedure, above.

(Use only one ground-marked hole for ground connection.)

7.If the supply cord of this appliance is damaged, it must be replaced by an exact replacement part. (The special cord means the cord which has the

same specification marked on the supply cord	Figure 17
fitted to the unit.)

2.3.6 P.C.B.

1.Remove the escutcheon.

2.Remove the two knobs.

3.Remove the 2 screws which fasten P.C.B. cover.

4.Disconnect all the leads which connected to the P.C.B.

5.Remove the two screws which fasten the P.C.B. board.

6.Re-install the components by referring to the removal procedure, above.

WARNING

After servicing control box ,make sure that AC and DC wires are separated and tied up properly.

The wires should also be pressed a little downwards to prevent touching it to the display pcb.

Figure 18

—15—

2.4 REFRIGERATION CYCLE

CAUTION

Discharge the refrigerant system using a refrigerant recovery system.

If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the refrigerant. Leave the valve in place after servicing the system.

2.4.1 CONDENSER

1.Remove the brace and the shroud. (Refer to section 2.2.2)

2.Remove the 4 screws which fasten the shroud. (Refer to section 2.2.2)

3.Push forward the shroud and remove the 2 screws which fasten the condenser with the basepan.

4.After discharging the refrigerant completely, unbraze the interconnecting tube at the condenser connections.

5.Remove the condenser.

6.Re-install the components by referring to notes. (See Figure 19)

2.4.2 EVAPORATOR

1.Remove the front grille. (Refer to section 2.1.1)

2.Discharge the refrigerant completely.

3.Remove the control box assembly. (Refer to section 2.1.2)

4.Remove the 4 screws which fasten the evaporator at the left side and the right side.

5.Move the evaporator sideward carefully and then unbraze the interconnecting tube at the evaporator connectors.

6.Remove the evaporator.

7.Re-install the components by referring to notes. (See Figure 20)

2.4.3 CAPILLARY TUBE

1.After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.

2.Remove the capillary tube.

3.Re-install the components by referring to notes.

Figure 19

Figure 20

—16—

NOTES

—Replacement of the refrigeration cycle.

1.When replacing the refrigeration cycle, be sure to discharge the refrigerant system using a refrigerant recovery system.

If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the refrigerant. Leave the valve in place after servicing the system.

2.After discharging the unit completely, remove the desired component, and unbraze the pinch-off tubes.

3.Solder service valves into the pinch-off tube ports, leaving the valves open.

4.Solder the pinch-off tubes with service valves.

5.Evacuate as follows.

1)Connect the vacuum pump, as illustrated Figure 16 A.

2)Start the vacuum pump, slowly open manifold valves A and B with two full turns counterclockwise and leave the valves closed. The vacuum pump is now pulling through valves A and B up to valve C by means of the manifold and entire system.

CAUTION

If high vacuum equipment is used, just crack valves A and B for a few minutes, then open slowly with the two full turns counterclockwise. This will keep oil from foaming and being drawn into the vacuum pump.

3)Operate the vacuum pump for 20 to 30 minutes, until 600 microns of vacuum are obtained. Close valves A and B, and observe the vacuum gauge for a few minutes. A rise in pressure would indicate a possible leak or moisture remaining in the system. With valves A and B closed, stop the vacuum pump.

4)Remove the hose from the vacuum pump and place it on the charging cylinder. See Figure 16 B. Open valve C.

Discharge the line at the manifold connection.

5)The system is now ready for final charging.

6.Recharge as follows :

1)Refrigeration cycle systems are charged from the high-side. If the total charge cannot be put

in the high-side, the balance will be put in the suction line through the access valve which you installed as the system was opened.

2)Connect the charging cylinder as shown in Figure 16B.

With valve C open, discharge the hose at the manifold connection.

3)Open valve A and allow the proper charge to enter the system. Valve B is still closed.

4)If more charge is required, the high-side will not take it. Close valve A.

5)With the unit running, open valve B and add the balance of the charge.

a.Do not add the liquid refrigerant to the lowside.

b.Watch the low-side gauge; allow pressure to rise to 30 lbs.

c.Turn off valve B and allow pressure to drop.

d.Repeat steps B and C until the balance of the charge is in the system.

6)When satisfied the unit is operating correctly, use the pinch-off tool with the unit still running and clamp on to the pinch-off tube. Using a tube cutter, cut the pinch-off tube about 2 inches from the pinch-off tool. Use sil-fos solder and solder pinch-off tube closed. Turn off the unit, allow it to set for a while, and then test the leakage of the pinch-off connection.

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