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

Page 1
LG
Packaged Terminal
Air Conditioner/Heat Pump
SERVICE MANUAL
LG
CAUTION
• BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.
• FOR AUTHORIZED SERVICE ONLY.
Page 2
—2—
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.
CONTENTS
Page 3
—3—
1.1 SPECIFICATIONS
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
Model Name Cooling (Btu/h) Cooling Watts (W) EER Electric Heat
Rated Amp,
Cooling
Mini Circuit
Protection (Amps)
Cooling/Electric Heater
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
Model Name
Cooling
(Btu/h)
Cooling
Watts (W)
EER
Reverse
Cycle (Btu/h)
COP Electric Heat
Rated Watts,
Heating
Rated Amp,
Cooling
Rated Amp,
Heating
Mini Circuit
Protection (Amps)
Cooling/Heat Pump/Electric
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
Page 4
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.
• 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—
THE SLEEVE AND THE REAR GRILLE
(Available as an option)
REAR GRILLE (Aluminum Rear Grille)
AIR FILTER
VERTICAL AIR DEFLECTOR
(Horizontal Louver)
SLEEVE ASSEMBLY (Including Aluminum Rear Grille)
R
O
O
D
N
I
INLET GRILLE
(Air Intake)
EXPANDED METAL GRILLE
(Superior for a performance)
Page 5
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—
Page 6
—6—
1.3 CONTROL LOCATIONS
OPERATION
ELECTRIC HEATING MODEL COOLING ONLY MODEL
VENT OPEN
VENT
CLOSE
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.
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.
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.
When the air conditioner has performed a cooling or heating operation and is turned off or set to the fan position, wait at least 3 minutes before resetting to the cooling operation.
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.
CAUTION
NOTE
Page 7
—7—
ELECTRONIC CONTROLS
The controls will look like one of the following.
TEMP/TIME
MODE
HEATHEAT
E/SAVEE/SAVE
FANFAN
COOLCOOL
HIGHHIGH
LOWLOW TIMERTIMER
FAN TIMER
'
F
ON
OFFONOFF
REMOTE CONTROL SIGNAL RECEIVER
POWER
MODE
-
Push this button to cycle through the modes from COOL FAN
HEATCOOL.
- 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
- 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.
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.
FAN SPEED
• Every time you push this button, it cycles through the settings as follows:
{High Low High Low}
• 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.
F1 LOW F2 HIGH
Page 8
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.
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.
—8—
ON
ONREMOTE
OFF
ON ON ON
Remote/Local Energy Saver Temperature Limit 1 Temperature Limit 2 Temperature Limit 3
LOCALLOCAL
1
OFF
OFF
2
OFF
OFF
3
OFF
OFF
4
OFF
OFF
5
LOCAL
1
OFF2OFF3OFF4OFF
5
LOCALLOCAL
1
OFF
OFF
2
OFF
OFF
3
OFF
OFF
4
OFF
OFF
5
LOCAL
1
OFF2OFF3OFF4OFF
5
Temperature Temperature Temperature
Limit #1 Limit #2 Limit #3
OFF OFF OFF 54° F (12.2° C) 86° F (30.0° C)
ON OFF OFF 56° F (13.3° C)
OFF ON OFF 58° F (14.4° C)
ON ON OFF 60° F (15.5° C)
OFF
ON OFF ON 64° F (17.7° C)
OFF ON ON 66° F (18.9° C) 74° F (23.3° C)
ON ON ON 68° F (20.0° C) 72° F (22.2° C)
OFF ON 62° F (16.6° C)
#6
ON ON
Cooling Operation
Heating Operation
Lowest Temp. Highest Temp. Lowest Temp. Highest Temp.
#7
86° F (30.0° C) 86° F (30.0° C) 86° F (30.0° C)
86° F (30.0° C) 86° F (30.0° C) 86° F (30.0° C) 86° F (30.0° C)
54° F (12.2° C) 54° F (12.2° C) 54° F (12.2° C) 54° F (12.2° C) 54° F (12.2° C) 54° F (12.2° C) 54° F (12.2° C) 54° F (12.2° C)
Unit Type
86° F (30.0° C) 84° F (28.9° C) 82° F (27.8° C) 80° F (26.7° C) 78° F (25.5° C) 76° F (24.4° C)
Cooling+Electric HeaterOFFOFF Cooling OnlyONOFF
OFF
ON
Heat Pump Only Cooling Only+Heat Pump
Page 9
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.
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.
—9—
GL GH O W Y R CLO LI
Front Desk Switch
LO LI GL GH O W Y R C
Low Fan
High Fan
Reversing V alve
Heater
Compressor
24 Volt-L
24 Volt-N
Wiring Schematic for Remote Heat Pump
Wiring Schematic for Straight Cool Unit.
Note: The following figures show wiring
schematics for heat pump and straight cool units with electric heat, respectively.
Wire # AWG Maximum Length
#22
600 ft (180 m) #20 900 ft (270 m) #18 1500 ft (450 m) #16 2000 ft (610 m)
Page 10
—10—
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 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.
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.
2. DISASSEMBLY INSTRUCTIONS
— Before the following disassembly, POWER SWITCH is set to OFF and disconnected the power cord.
Figure 1
40˚
15˚
Screws
Page 11
—11—
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.
4. Remove the control box cover. (See Figure 3)
5. Disconnect wire housings on the control box.
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 2
Figure 3
Figure 4
Page 12
Figure 8
—12—
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.
(See Figure 5)
4. Remove the top cover assembly, net steel, brace.
(See 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)
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 5
Figure 6
Figure 7
Page 13
—13—
Figure 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)
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.
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.
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 9
Figure 10
Figure 11
Page 14
—14—
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.
2.3.2 INDOOR MOTOR (Refer to section 2.2.2)
2.3.3 COMPRESSOR
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.
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 13
Figure 14
Figure 15
Figure 16
Page 15
—15—
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 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
Figure 17
Figure 18
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.
Page 16
—16—
2.4 REFRIGERATION CYCLE
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 15
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.
CAUTION
Figure 20
Page 17
—17—
— 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.
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 low-
side.
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.
NOTES
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.
CAUTION
Page 18
—18—
Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment. pinch-off tool capable of making a vapor-proof seal, leak detector, tubing cutter, hand tools to remove components, service valve.
A
COMPOUND GAUGE
EVAPORATOR (LOW PRESSURE SIDE)
COMPRESSOR
CAPILLARY TUBE
CONDENSER (HIGH PRESSURE SIDE)
SEE INSETS
BELOW
MANIFOLD
GAUGE
B
Figure 16 A-Pulling Vacuum
Figure 16 B-Charging
A
B
EXTERNAL VACUUM PUMP
LOW
B
HI
A
CHARGING CYLINDER
C
Page 19
—19—
3. INSTALLATION
3.1 HOW TO INSTALL THE UNIT
For existing sleeve, you should measure the wall sleeve
dimensions. Install the new air conditioner according to these installation instructions to achieve the best performence. All wall sleeves used to mount the new air conditioner must be in good structural condition and have a rear grille that securely attaches to the sleeve or the flange of the sleeve to secure the new air conditioner.
• To avoid vibration and noise, make sure the unit is installed securely and firmly.
When installing the sleeve, make certain there is nothing within 20" of the back that would interfere with heat radiation and exhaust air flow.
Insulation strip must be attached to prevent the re­circulation of exhaust air to inward side from the either side of condenser space. The insulation strip is provided with the box. Refer to the diagram below.
1) Take out the insulation strip from the upper packing.
2) Attach the insulation strip onto the rear upper side of the
wall sleeve.
3) To improve unit energy efficiency, it is recommended the
change of outside grille for an unit protection and an addition of a plastic rear grille. (This is optional.)
4) Insulation strip prevents the exhaust air from re-entering
from either side of condenser space which may decrease the cooling efficiency of condenser.
Recommended
406 mm
(16")
406 mm
(16")
1,066 mm
(42")
1066 mm
(42")
318 mm (12 1/2")
318 mm (12 1/2")
505 mm
(20")
Over 20"
HEAT
RADIATION
WALL
WALL
INSULATION SLEEVE
INTAKE
AIR
COOLED
AIR
1/4" Bubble
of the level
Front
Insulation Strip
Rear
Sleeve
280 mm
(11")
• There are sharp edges that can cause serious cuts.
• When lifting the air conditioner, it is HEAVY.
Use 2 people to lift.
CAUTION
Dimension of air conditioner
Dimension of sleeve assembly (optional)
Page 20
—20—
3.2.1 PREPARATION OF SLEEVE
ASSEMBLE THE WALL SLEEVE
• Raise the sleeve side panels to upright position as shown on the right.
• Place sleeve upper on top of side panels.
• Fasten the four screws as shown on the right.
• Assemble the drain kit.
• Fasten this assembly to the each side of the wall sleeve as shown on the right.
• Assemble the outdoor grille and fasten the 4 screws as shown on the right.
3.2.2 PREPARATION OF THE FRONT GRILLE
Carefully remove shipping tape from the front grille.
SCREWDRIVER (FLAT and PHILLIPS), RULER, KNIFE, HAMMER, PENCIL, LEVEL
INDOOR
3.2 SUGGESTED TOOL REQUIREMENTS
SLEEVE HARDWARE
NUMBER NAME OF PARTS Q’TY
LOVER SLEEVE 1 UPPER SLEEVE 1 SCREW 4 OUTDOOR GRILLE 1 DRAIN KIT 1
12
14
R
O
O
D
N
11
I
R
O
O
D
IN
R
O
O
D
N
I
I
N
D
O
O
R
R
O
O
D
N
I
Shipping Tape
Page 21
—21—
3.2.3 UNIT INSTALLATION
1. Remove the shipping screw from the ventilation door. (See Figure 17)
2. Remove the front gille by pulling it out at the bottom to release it, then lift it up along the unit top front. (See Figure 18)
3. Slide the unit into the wall sleeve and secure with 6 screws through the unit flange holes. (See Figure 19)
4. Reinstall the front grille by hooking the top over the unit top, then pushing it in at the bottom. (See Figure 20)
Figure 17
Figure 18
Figure 19
Figure 20
Page 22
—22—
Perpendicular
20 A
Tandem
15 A
Large T andem
30 A
230/208 volt receptacle configuration
CAUTION
1. Do not use an extension cord with this unit.
2. When the unit is in the OFF position, the power supply to the electrical controls is still energized.
3. Disconnect the power to the unit before servicing the unit.
4. Remove the power cord from the wall receptacle.
5. Remove or turn off the protective device (fuses or circuit breaker).
Wirings including installation of the receptacle must comply with the NEC and local codes, local regulations.
FUSE- Use a time-delay fuse or circuit breaker. Refer to the nameplate
for proper power supply requirements.
3.3.1 ELECTRICAL DATA (FOR 230/208V MODEL)
3.3.2 ELECTRICAL SAFETY
IMPORTANT GROUNDING INSTRUCTIONS
The air conditioner has a three-prong grounding plug on its power supply cord which must be plugged into properly grounded three-prong wall receptacle for your protection against possible shock hazard.
FUSE – Use a time-delay fuse or circuit breaker. Refer to the nameplate for proper power supply requirements. 208, 230, and 208/230 VOLT UNITS
These units are equipped with a three-prong grounding plug on the power supply cord which must be plugged into a matching properly grounded three-prong wall receptacle for your protection against possible shock hazard. If such an outlet is not present, one must be installed by a qualified electrician in accordance with the National Electrical Code and local codes and ordinances.
NOTE: DO NOT USE AN EXTENSION CORD on 208, 230, and 208/230 Volt units.
3.3 ELECTRICAL REQUIREMENTS
Page 23
—23—
Control Panel Key Lock
Part No: AYCP101
Description
The Key Lock kit prevents tampering of the controls used to set temperatures and heating or cooling functions.
Receiving
Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt. Unit must be stored in its original shipping carton in a dry, secure place prior to its installation and use.
Installation
The installation and servicing of the equipment referred to in this booklet should be performed by qualified, experienced technicians.
1. Remove front from unit by pulling bottom out and then lifting upward. (Figure 21)
2. Remove existing door assembly by lifting door halfway and using both hands, bow door just enough for door hinge pins to slide out of mating holes. (Figure 22)
3. Install the new door assembly with the key lock by bowing the door with both hands and aligning the door hinge pins with their bracket in the front. (Figure 23)
Important Note:
Personal Risk Hazard Underwriter’s Laboratories Inc. listed. For institutional use only where supervisory monitoring is available. Any other use may increase the risk of personal injury or property damage.
Note: The installation and servicing of this equipment must be performed by qualifieed.
experienced technicians
NOTICE:
Warnings and Cautions appear at appropriate sections throughout this manual. Read these carefully.
WARNING - Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION - Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
CAUTION –Indicates a situation that may result in equipment or property-damage-only accidents.
4. FIELD INSTALLED ACCESSORIES
Door
Front
Hinge Pins (Each Side)
Brackets (Each Side)
Figure 21 - Remove Front
Figure 22 - Door Removal
Figure 23 - New Door Installation
Page 24
—24—
Condensate Disposal Pump Kit Installation
Part No: AYSB2101
Description
The internal condensate pump serves as a means for disposing of condensate generated during heat pump operation by transferring it to the indoor coil. The warm coil surface and the warm room air help in evaporation of the condensate while adding humidity to the room. As with any equipment of this type, the addition of this kit will decrease the effective heating capacity of the unit. This kit is not intended for use in seacoast or corrosive environments.
NOTE:
Under extreme high humidity conditions, the internal condensate pump may not be able to dispose of all the condensate produced, and condensate would then drip from the outside of the wall sleeve. If this condensation is unacceptable, then a drain system (including factory approved drain kit for the wall sleeve) should be installed.
Receiving
Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt. Unit must be stored in its original shipping carton in a dry, secure place prior to its installation and use.
Installation
The installation and servicing of the equipment referred to in this booklet should be performed by qualified, experienced technicians.
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
Important Note:
The unit OFF switch does not disconnect all electrical power to this unit.
1. Remove front by rotating bottom outward and then lifting up and out from chassis.
2. Unplug and remove the PTAC chassis from the wallsleeve. Move the chassis where the front and back of the chassis can be easily accessed.
3. Remove the top cover assembly, net steel.(Figure 24)
4. Lift the heater/discharge deck assembly approximately 10 inches by unscrewing three screws (two on the left side, one on the right side of the discharge deck) holding the discharge deck to the chassis. Lift upward being careful not to pinch heater wires. (Figure 25)
5. Place coil cover on top of the evaporator coil with flanges pointing down. Make sure cover is over entire top of coil. (Figure 25)
6. Position the short end of the condensate tube through the back wall of the partition panel using existing hole. The condensate tube should protrude through the partition panel by 1-3/4 inches. Rotate the condensate tube so the tube lays flat on the coil cover. (Figures 25 & 26)
Mounting Screws
Condensate T ube
Figure 24
Figure 25
Page 25
—25—
7. Position the condensate tube through existing hole (located right side of blower deck).
8. Make sure the holes in the condensate tube are facing inward toward the blower wheel.
9. Lower the discharge deck over the condensate tube and screw the discharge deck to the chassis with the existing screws. Replace the discharge screen and screw the screen to the discharge deck with the existing screws.
10. Using the overflow tube holder and the overflow tube,
hold the tube with the metal holder and screw the holder to the partition panel with the provided 1/2 inch #8 screw. (Figures 27 & 28)
11. Place the pump bracket onto the end of the pump by feeding the pump cord through the hole in the bracket and pushing the bracket onto the threads of the pump. Slide the supplied washer onto the threads of the pump. Screw the pump nut onto the threads of the pump and tighten the nut so that the bracket is secure against the pump. (Figure 29)
12. Position the pump in the back left corner of the basepan and screw the pump bracket to the basepan with the provided two 1/2 inch #8 screws. (Figure 30)
13. Remove the protective adhesive backing from the plastic U clip and mount the U clip to the plastic condenser shroud in approximately the position shown. (Figure 31)
14. Snap the provided round plastic grommet into the top condenser baffle. (Figure 31)
Condensate T ube
Screws
Holder
Tube
Figure 26
Figure 29
Figure 30
Figure 27
Figure 28
Page 26
—26—
15. Place one of the hose clamps over one end of the 16-inch vinyl hose. Place the same end over the barbed discharge tube of the pump assembly. Place a hose clamp on the other end of the 16 inch hose. Place this same end over the shorter leg of the overflow tube and secure the hose with the hose clamp. (Figure 31)
16. Place a hose clamp over one end of the 11-inch long hose. Push this same end over the longer leg of the over­flow tube and secure with the hose clamp. Place another hose clamp over the other end of the 11-inch hose. Push this same end over the condensate tube protruding out from the back of the partition panel and secure with the hose clamp. (Figure 31)
17. Route the condensate pump cord through the U clip on the condenser shroud, through the plastic grommet in the sheet metal condenser wing, through the plastic ring in the panel, and then through the hole in the panel where the compressor wires are routed through the panel.
NOTE: The permagum may have to be removed to feed the wires through the panel, make sure wires have no slack and replace the permagum to prevent air leaks. (Figures 31 and
32)
18. To gain access inside the control panel, remove the knobs and escutcheon. Remove the two screws holding the panel in position. Tilt the control panel forward, being careful not to pinch any wires. (Figure 33)
19. Lift the control panel up so the control panel is free of its hinges. Position the control panel so there is easy access for mounting components to the control panel. (Figure 33)
20. Connect the condensate pump to the ICR relay on the terminal board per Figure 34.
21. For 208 volt applications move the WH6 wire terminal from the 240 volt terminal of the transformer to the 208 terminal of the transformer.
22. Install the basepan drain plug into the basepan drain hole by pushing it up into the drain hole from the bottom of the basepan. This will defeat the thermostatic controlled drain valve. The basepan drain is located to the left of the outside coil (as viewed from the back of the unit).
U Clip
Plastic Grommet
Overflow Tube
Figure 31
Permagum
Plastic Ring
Grommet
Condensate Pump Cord
Figure 32
Mode Switch
Thermostat
Remove two screws to gain access inside Control Panel
Fuse Holder Knockouts under panel
Figure 33
Figure 34 - Internal Condensate Removal Pump
Wiring
Page 27
—27—
Architecture Grille Aluminum - Single Pack
Part No: AYAGALA01
Description
Outdoor grilles are attached to the wall sleeve and exposed to the exterior wall. The grilles are an industry standard size of 42" x 16".
Receiving
Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt. The unit must be stored in its original shipping carton in a dry, secure place prior to its installation and use.
Installation
The installation and servicing of the equipment referred to in this booklet should be performed by qualified, experienced technicians.
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
Important Note:
The unit OFF switch does not disconnect all electrical power to this unit.
Note:
A baffle kit must not be used with a stamped aluminum grille on any PTAC installation.
Stamped Aluminum Grille
1. Prepare the wall sleeve for installation of the grille by
removing the cardboard stiffener and rear enclosure panel from the sleeve. These items may be removed from inside of the building.
Note:
The sleeve stiffener must be taken out before the rear sleeve enclosure panel can be removed from the sleeve.
2. Prepare the stamped aluminum grille for installation on the
sleeve by inserting the six (6) plastic grommets into the square holes located near the outer edges of all four sides of the grille. With the grille positioned so the flanges of all four sides are in the up position, insert the grommets so the square end protrudes through the grille in the opposite direction from the flanges.
3. Turn the grille so it can be removed through the rear sleeve
opening.
4. Install the stamped aluminum grille by aligning the guide
pins located in the lower right and left hand corners of the grille with the corresponding holes in the rear of the wall sleeve.
5. Secure the grille by threading each of the screws into the
plastic grommets.
6. Remove the wire handle (not shown in the picture) from the
center of the grille prior to installing the chassis into the sleeve.
Note:
Be sure to keep a firm grip on wire handle and grille to prevent it from dropping and/or causing possible injury or property damage.
Architectural Grille
1. Remove the cardboard sleeve stiffener and the rear
enclosure of the sleeve as described in Step 1 of the stamped aluminum grille instructions.
2. Turn the grille so it can be removed through the rear sleeve
opening.
3. Install the grille by aligning the four screws supplied to their
corresonding holes in the architectural grille.
Stamped Aluminum Grille
Architecture Grille
Page 28
—28—
4. Secure the grille to the sleeve by tightening the four screws to their corresponding holes in the grille.
5. Remove the wire handle after the installation is complete.
Note:
The stamped aluminum grille includes 6 screws, washers, nuts, and plastic grommets. The architectural grille includes 4 screws.
Condensate Drain kit
Part No: AYDR101
Description
Condensate water will drain from the chassis into the sleeve during normal heat pump operation. This can also occur during times of high humidity when in cooling operation. Install either the outdoor or indoor drain kit components to control the condensate water where normal drainage from the wall sleeve is not possible or undesirable. See Figure 35 for all components of the drain kit.
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
Important Note:
The unit OFF switch does not disconnect all electrical power to this unit.
Receiving
Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt. The product must be stored in its original shipping carton in a dry, secure place prior to its installation and use.
Installation
The installation and servicing of the equipment referred to in this booklet should be performed by qualified, experienced technicians.
Drain Installation
Note:
The optional drain kit serves only as a link between the unit and field-supplied condensate drain system. Installing the kit without connecting it to a drainage system will result in inadequate condensate removal, possible leakage and corrosion.
Algaecide: Some algaecide products may cause damage to the unit basepan and therefore should not be used. Contact your sales representative when considering the use of a commercial algaecide. See Figure 35 for components of the drain kit.
DRAIN FITTING
PLATE B
BLANK-OFF
PLATE C
BLANK-OFF
PLATE C
GASKETS A
1/2" DRAIN FITTING
MTG. SCREWS
MTG. SCREWS
BLANK-OFF
PLATE D
GASKET E FOR
PLATE D
Figure 35 – Components of Drain Kits
Page 29
—29—
Outdoor Drain Kit Installation
Before installing the wall sleeve louvered condenser grille, it must be determined if the optional outdoor wall sleeve drain kit is to be installed. The drain kit will allow the condensate from the outdoor and indoor coils to be routed to a suitable area. The drain kit can be installed so the condensate can be drained from the right or left hand side of the wall sleeve. See Figure 36. See local codes for proper condensate disposal.
To install the outdoor drain components proceed as follows:
1. Remove the rear enclosure panel and the sleeve stiffener. These items may be removed from the inside of the building.
2. The drain fitting can be installed on the left or right hand side of the sleeve. (Illustration will be for a right hand installation.) Insert the drain fitting in the opening of gasket A and hole of plate B. Secure this assembly to the rear of the sleeve with two sheet metal screws into holes G provided in sleeve. See Figures 37 and 38.
3. Locate the other gasket A on the back of blank off plate C and secure the assembly to the left rear of wall sleeve with sheet metal screws provided. See Figure 39 for finished left hand side installation.
If the unit chassis is to be installed right away, install the condenser grille to wall sleeve with hardware provided. See condenser grille installation instructions.
If the unit chassis will not be installed right away, replace the rear enclosure panel in the wall sleeve. This will help protect the inside of the building from weather damage.
If a subbase is used, be sure the right hand subbase cover is removed before the chassis is installed in the sleeve. Slide the chassis into the wall sleeve until the chassis flanges
contact the front edge of sleeve. Secure the chassis to the wall sleeve on each side with screws provided.
Re-install the cabinet front.
See the following pages for installation instructions of indoor drain kit.
1/2" DRAIN
FITTING
DRAIN FITTING
PLATE B
GASKETS A
MTG. SCREWS
BLANK-OFF
PLATE C
Figure 36 – Outdoor Drain Kit Installation
G
PLATE "B"
DRAIN FITTING
BLANK-OFF PLATE
SHEET METAL SCREWS
Figure 37 Figure 38
Figure 39
See Detail A
Sleeve overflow port Do not close up this port
Gasket
MTG. Screws (2)
1/2" Outdoor Drain Fitting
Detail A
Cover
Plate
Wall Sleeve Bottom
(4) Mounting Screws
Gasket (2)
Blank-off Plate (2)
Figure 40
Page 30
—30—
Indoor Drain Kit Installation
The internal drain is installed on the bottom of the wall sleeve when it is required to drain the condensate into a drain system inside of the building. The components of the wall sleeve drain kit are shown in Detail A. Use components C (2), D, E, mounting screws (6) and the Outdoor drain fitting.
1. The components D, E, and drain fitting of the kit are mounted on the bottom of the wall sleeve prior to the installation of the sleeve. It may be located in a feasible area on the bottom of the sleeve which is inside of the room except when a subbase is used. When a subbase is installed, the drain may be a minimum of 3 1/2 " from the front flange of the wall sleeve. The minimum clearance should provide adequate clearance for the subbase, see Figures 40 and 41.
2. Cut out the template in the lower right hand corner of these instructions to locate the field drilled holes. (Two to mount the plate and one for the Outdoor drain fitting). See Detail A on how the components have to be installed after the holes are drilled in the bottom of the wall sleeve. If the drain fitting is not connected to an indoor drainage system immediately after the wall sleeve is installed, it must be plugged with a cork to prevent indoor water damage in case it rains.
An indoor tube or hose (furnished by others) must be installed on the drain fitting and interconnected to the drain system inside of the building.
Install the two blank-off plates C and gaskets A on the outdoor portion of the wall sleeve as shown in Figure 40. These components may be installed after the sleeve is secured in the wall opening just prior to the installation of the condenser grille and chassis.
Leveling Legs
Part No: AYLL101
Description
Leveling legs are designed to provide extra front support and leveling of the wall sleeve. Two leg assemblies are required per unit and are provided in each kit. Four screws are also provided with each kit for attachment to the wall sleeve. See Figure 42.
The leveling legs must be installed before the chassis is installed, but after the wall sleeve is in place. Holes must be drilled in each side of the wall sleeve, below the duct package holes, for attachment to the wall sleeve.
Receiving
• Compare kit identification number with sales order to ensure that the correct kit has been received.
• Inspect the leveling legs for shipping damage. File damage claims with the delivering carrier immediately.
Installation
The installation and servicing of this equipment should be performed by qualified, experienced technicians.
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
Important Note:
The unit OFF switch does not disconnect all electrical power to this unit.
Checklist
The following is an abbreviated guide to leveling leg installation. Refer to appropriate areas for more detailed information.
Figure 41
Page 31
—31—
Leveling Leg Assembly
To install the leveling leg assembly, complete the following:
1. Drill two 1/8-inch holes in each side of the wall sleeve, as shown in Figure 43, using the leveling leg assembly as a template. Locations near the front of the sleeve provide more support.
2. Adjust the leveling legs to the approximate height needed and install them on either side of the wall sleeve, using the screws provided. Bottom of wall sleeve can be anywhere from three to five inches above the screw base. Caulk around screws to prevent water leaks.
3. Level the sleeve horizontally from side-to-side. Provide a slight slope (one-quarter bubble in the sight glass) toward the outside. Check the level again after the unit has been installed. Adjust the legs as needed.
Installation on Wall Sleeve
1. Drill four 1/8-inch diameter holes in the wall sleeve, two on each side, using the leveling legs as a template. Caulk around screws to prevent water leaks.
2. Attach the legs to the wall sleeve, using the screws provided.
3. Adjust the leveling legs to level the wall sleeve from side to side and provide a slight pitch to the outside (one-quarter bubble in sight glass).
Adjuster Screw
Speed Grip Nut
Leveler Bracket
1/8" Diameter holes
(four required per unit field-drilled)
1"
1/4"
1/2"
NOTES:
1. Two leveling legs are supplied in each kit.
2. One kit is required per unit.
3. Fout mounting screws are provided in each kit.
Figure 43 - Leveling Leg Assembly
Figure 44 - Leveling Leg Installation on Wall Sleeve
Page 32
—32—
Hard Wire Kit
Part No: AYAGALA01
Description
Hard Wire Junction Box (Direct Wire Sub-Base) The hard wire junction box kit is used to hard wire the unit when it is not desirable to use the standard unit subbase or the unit power cord. The junction box provides a protected enclosure for electrical connections as required by some electrical codes. The hard wire junction box is intended to be mounted on the floor or the adjacent wall.
The junction box is furnished with approximately 2-1/2 feet of 1/2-inch flexible steel conduit and a metal box for securing the conduit to the unit cabinet at the incoming power opening.
An optional 230/208V or 265V power switch assembly is available for use with the hard wire junction box or subbase. The switch provides a POWER ON/OFF function at the unit as required by some electrical codes. A replacement junction box cover plate is provided with each switch kit. For additional information, refer to the Power Switch Installation Instructions.
Receiving
Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt. Unit must be stored in its original shipping carton in a dry, secure place prior to its installation and use.
Installation
The installation and servicing of this equipment should performed by qualified, experienced technicians.
Junction Box Kit Installation and Wiring Procedure
EIectrical connections at the unit must be made after the unit chassis is installed in the wall sleeve. The installer must determine and supply the mounting components for attaching the junction box to the wall or door.
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
Important Note:
The unit OFF switch does not disconnect all electrical power to this unit.
CAUTION Use Copper Conductors Only!
Unit terminals are not designed to accept other types of conductors. Failure to use copper conductors may result in equipment damage.
Important Note:
All wiring must comply with applicable local and national codes. Types and location of disconnect switches must comply with all applicable codes.
1. Remove the cover plate from the junction box
2. Mount the junction box to the wall or floor within 28 inches (711
mm) of the lower right corner of the wall sleeve.
3. If a disconnect switch is to be used, make electrical
connections to it and mount the switch in the junction box. Refer to the Power Switch Installation Instructions.
4. Remove control panel assembly by removing the two screws
holding control panel in place. Rotate the panel forward.
5. Disconnect the power cord leads from all electrical connections
including the ground wire.
6. Remove the power cord clamp and the power cord from the
unit.
7. For 208/230-volt units, remove and discard the white lead from
the wire assembly. For 265-volt units, remove and discard the red lead from the wire assembly.
8. Remove the retaining ring from the threaded portion of the
straight conduit clamp. Insert the three wires into the metal box through one of the two openings in the box. Replace the hole cover grommet into the unused hole to prevent objects from entering the box.
9. Replace the retaining ring back on the conduit clamp inside the
metal box and tighten the ring securely.
10. Insert the three wires extending from the metal box into the
incoming power opening on the unit so that approximately 20 inches (508 mm) of the wires protrude through the opening.
11. Attach the metal box to the chassis with the two screws
provided. See Figure 45.
12. Insert the wire tie into the 1/4-inch diameter hole located just
above the incoming power opening. Tie all wires together securely with the wire tie. See Figure 46.
Page 33
—33—
208/230 Volt Units
1. Remove and discard the white lead from the wire assembly.
2. Connect the black lead to the line 2 terminal on the control board.
3. Connect the red lead to the common (C) terminal on the capacitor.
4. Connect the ground wire to the partition panel where the ground wire on the power cord was located. Use the supplied green ground screw.
5. Connect the red lead in the wire assembly at the junction box to the red lead of the field power source.
6. Connect the black lead in the wire assembly at the junction box to the black lead of the field power source.
7. Connect the ground wire of the field power source to the ground wire of the wire assembly at the junction box.
8. Install the junction box cover plate.
9. Reinstall the control panel assembly.
265 Volt Units
1. Remove and discard the red lead from the wire assembly .
2. Connect the black lead to the center terminal of the fuse holder.
3. Connect the white lead to the common (C) terminal on the capacitor.
4. Connect the ground wire to the partition panel where the ground wire on the power cord was located. Use the supplied green ground screw.
5. Connect the white lead of the wire assembly at the junction box to the white lead of the field power source.
6. Connect the black lead of the wire assembly at the junction box to the black lead of the field power source.
7. Connect the ground wire of the field power supply to the bare ground wire of the wire assembly at the junction box.
8. Install the junction box cover plate.
9. Reinstall the control panel assembly.
Figure 47 - Electrical Wiring Routing
Figure 46 - Metal Box Location
Figure 45 - Mounting Hard Wire Junction Box Kit
Wall Sleeve
Ground Wie
with Eyelet
Terminal
Cover plate
28 Inch es Max
Conduit
with Straight Clamp
Power Leads
with Push on
Connectors
Metal Box
Control Panel
Base Pan
Bracket
Right Side of Chassis
Wire Tie
3/16 Inch
Diamenter Hole
Electrical Supply Wires
Back of Control Panel
Page 34
—34—
Fuse Holder Kit
Part No: AYFH1101
Description
This optional fuse holder kit can be installed directly in the chassis or in the optional subbase. Fuse holder kits are available in 230/ 208 volt ratings. The installer should supply time delay fuses at 15, 20, 25, or 30 amps in accordance with the Maximum Overcurrent Protection as listed on the unit nameplate. Fuses may be purchased from the parts department.
Note:
The installation and servicing of this equipment must be performed by qualified, experienced technicians only.
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
Important Note:
The unit OFF switch does not disconnect all electrical power to this unit.
CAUTION Use Copper Conductors Only!
Unit terminals are not designed to accept other types of conductors. Failure to use copper conductors may result in equipment damage.
Important Note:
All wiring must comply with applicable local and national codes. Type and location of fused disconnect switch(es) must comply with all applicable codes. Failure to follow these codes could result in overheating and equipment failure.
Receiving
Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt. Unit must be stored in its original shipping carton in a dry, secure place prior to its installation and use.
Installation
The installation and servicing of the equipment referred to in this booklet should be performed by qualified, experienced technicians.
Fuse Holder Kit Installation (Without Subbase)
1. Remove front by rotating bottom outward and then lifting up and out from chassis.
Mode Switch
Thermostat
Remove two screws to gain access inside Control Panel
Fuse Holder Knockouts under panel
Figure 48 - Control Panel
Page 35
—35—
2. To gain access inside the control panel, after removing the knobs and escutcheon, remove the screws holding panel in position. Tilt control panel forward, being careful not to pinch any wires. (Figure 48)
3. As viewed from the front, remove both knockouts on the control panel.
4. Insert two fuse holders from the front. The fuse holders should be oriented so the quick-connect tabs are toward the center of the unit. Attach fuse holders using the screws and nuts provided. (Figure 48)
5. Remove both power cord leads, one lead from the capacitor and one from the electronic board.
6. Install one power cord lead on the center terminal of one fuse holder. (Figure 49)
7. Install the remaining power cord lead on the center terminal of the second fuse holder. (Figure 49)
8. Connect BK-10 wire from the side terminal of one fuse holder to the Line terminal on the electronic board. (Figure 48)
9. Connect RD-10 wire from the side terminal of the other fuse holder to the common (C) terminal on the capacitor. (Figure 49)
10. Tilt control panel back to original location, being careful
not to pinch any wires. Align the control panel with the cover and screw panels into place with original screws. Replace escutcheon and control knobs.
Fuse Holder Kit Installation (With Subbase)
See previous section for installation in the control panel.
1. Remove both knockouts at the fuse holder location. (Figure 50)
2. Install the fuse holders using screws provided. The side connector tab on the fuse holders should be towards the left.
3. Connect a stripped BK-9 wire to the center of the quick­connect tab of the fuse holders. Wire nut the other end of this wire to the black field connection wire (TB1). (Figure 51)
4. Connect the other stripped BK-9 wire to the quick-connect tab on the side of the same fuse holder. Wire nut the other end to black subbase wire leading to receptacle. (Figure 51)
5. Connect the stripped RD-9 wire to the center quick-connect tab of the second fuse holder. Wire nut the other end to the red field connection wire (TB3). (Figure 51)
6. Connect the other stripped RD-9 wire to the quick-connect tab on the side of the second fuse holder. Wire nut other end to red subbase wire which leads to receptacle. (Figure 51)
7. Insert time delay fuses into the fuse holders. Size all fuses by the Maximum Overcurrent Protection shown on the nameplate. Also refer to the serial plate on the unit.
Figure 49 - Fuse Holder Diagram
Control Panel Installation
Figure 50 - Subbase (Left Side)
Figure 51 - Fuse Holder Diagram Subbase Installation
FUSEHOLDERS
WH
GN
BK
Terminal Blocks Behind
the Control Panel
Transformer
Status Light
Control Board
Fuse Holder
Knockouts
Leveling
Leg
Power Switch
Knockouts
Electrical
Receptacle
Fuseholder
Fuseholder
BK-9
RD-9
Field Connection
Wiring
Green
Black
Red
Page 36
—36—
Remote Escutcheon Kit
Part No: AYRE110
Description
This kit provides an attractive replacement escutcheon (see Figure 52). The kit allows the removal of control knobs and graphics, which are not required when a wall thermostat is used to control the unit.
Receiving
Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt. The unit must be stored in its original shipping carton in a dry, secure place prior to its installation and use.
Installation
The installation and servicing of the equipment referred to in this booklet should be performed by qualified, experienced technicians.
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
Important Note:
The unit OFF switch does not disconnect all electrical power to this unit.
1. Grasp the cabinet front as shown in Figure 53.
2. Pull the bottom of the cabinet front away from the chassis until the retaining clips disengage as in Figure 54.
3. Lift the cabinet front off the chassis.
4. Lifting the front edge of the escutcheon, slide the tabs at the top of the escutcheon out of the retaining holes and remove the escutcheon. See Figure 55.
TEMP/TIME
MODE
HEATHEAT
E/SAVEE/SAVE
FANFAN
COOLCOOL
HIGHHIGH
LOWLOW TIMERTIMER
FAN TIMER
'
F
ON
OFFONOFF
F1 LOW F2 HIGH
Figure 51Standard Escutcheon
Figure 53
Figure 54
Page 37
—37—
5. Replace the escutcheon with the one from this kit by inserting the tabs at the top of the escutcheon into the retaining holes and laying the escutcheon flat on the control panel.
6. Replace the front by reversing steps 1 through 4.
7. Store the control knobs and escutcheon just removed from the unit for possible reinstallation if the wall thermostat is no longer desired.
Subbase
Part No: AYSB1101 (230/208V 20A)
AYSB2101 (230/208V 30A)
Description
The subbase may be installed on the wall sleeve before or after installing the wall sleeve. The subbase is prewired. Electrical connections can be made on the left side after the access cover is removed. A grounding screw is provided.
Receiving
Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt. The unit must be stored in its original shipping carton in a dry, secure place prior to its installation and use.
Installation
The installation and servicing of the equipment referred to in this booklet should be performed by qualified, experienced technicians.
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
Important Note:
The unit OFF switch does not disconnect all electrical power to this unit.
CAUTION Use Copper Conductors Only!
Unit terminals are not designed to accept other types of conductors. Failure to use copper conductors may result in equipment damage.
Note:
When using a subbase, the wall sleeve must be installed a minimum of 3-1/4 inches (83 mm) above a finished floor and a minimum of 2-3/
4 inches (70 mm) from a finished wall.
1. Remove parts B and C (Figure 57, next page) from the subbase and join together using two metal screws provided. This assembly now becomes the right front cover (Part F) of the subbase. (Figure 56, next page)
2. Position subbase under the front of the wall sleeve.
3. Align the back edge of the flange on cover A (Figure 57, next page) to front of the wall sleeve flange. (Figure 58, next page)
4. Drill four 1/8 inch holes in wall sleeve to line up with holes in subbase. (Figure 57, Location D, next page) Mount subbase to wall sleeve with four sheet metal screws provided with kit. (Figure 57, Location D, next page)
5. Remove the left front cover from the subbase. (Figure 57, Part A, next page)
6. Position skirting on each side of wall sleeve to prevent the entry of foreign materials. Trim skirting to desired length. Attach skirting with four sheet metal screws provided with kit. (Figure 57, Location E, next page)
7. Wire subbase for appropriate voltage (Figure 59, next page).
Escutcheon
Figure 55
Page 38
—38—
Note:
The proper subbase must be ordered to obtain the correct electrical receptacle. (Figure 60)
8. After wiring is complete, mount covers A and F to the subbase with provided screws. (Figure 57)
9. When installing optional accessories to the subbase, refer to each installation instruction for that accessory.
Figure 55
Figure 57 - Part/Location Identification
Figure 58 - Dimensions
Figure 59 - Wiring Diagram
Figure 60 - NEMA Plug Configurations
Wall Sleeve (Outdoor Side)
13 3/4"
16"
16"
2 5/8"
Left End View
2 3/4"
2 3/4"
Wall Sleeve Inside Edge
Back of Flange "A"
Part/Location Identification
A
Left Front Cover
B
Right Front Cover
C
Front Cord Panel
D
Wall Sleeve Hole Location
E
Skirting Hole Location
F
Right Cover Assembly
Wall Sleeve
D
Concentric
2" (50 mm)
Ground Screw Location
13-7/8" (352 mm)
1-3/8" (35 mm)
Knockouts In Bottom
Top View
Receptacle Provided Inside subbase
3-1/16"
(78 mm)
Accessory
Concentric Knockouts In Rear
Front View
Field Wiring Line Voltage
NEMA 6-20R Receptacle
NEMA 6-30R Receptacle
230/208 VAC Field Schematic 265 VAC Field Schematic
NEMA 7-20R Receptacle
NEMA 7-30R Receptacle
20-5/16" (515.5 mm)
2" (50 mm) Max. Adjustment
Field Wiring Line Voltage
4" (101 mm)
2-5/8" (67 mm)
Cover Wiring Access
E
A
B
Subbase Box Assy
F
C
Low Voltage Compartment
D
E
11-13/16"
2-13/16" (71 mm)
(300 mm)
Voltage Subbase ReceptacleUnit Plug
Page 39
5. PERFORMANCE DATA
—39—
Voltage (V)
Cooling Data
Cooling Capacity (Btu/h)
Cooling Amps (A) Cooling Power (W) EER (Btuh/Watt) Moisture Removal
(Pts/h)
Airflow
Indoor CFM (Wet) @0.3ESP (Hi)
Indoor CFM (W
et)
@0.3ESP (Lo) Indoor CFM (Dry)
@0.3ESP (Hi) Indoor CFM (Dry)
@0.3ESP (Lo)
LP070CM*
208 230
7,400 7,600
2.8 2.6
595 610
12.5 12.5
2.0 2.0
185 215 145 175 210 240 170 200
LP090CM*
208 230
8,800 9,000
3.9 3.6
760 775
11.6 11.6
2.6 2.6
230 260 180 220 250 250 210 210
LP120CM*
208 230
11,500 11,800
4.8 5.2
1045 1075
11.0 11.0
3.6 3.6
300 330
290 290 320 350 280 310
LP150CM*
208 230
14,100 14,300
7.1 6.5
1470 1490
9.6 9.6
4.5 4.5
315 355 275 315 350 390 310 350
Voltage (V)
Cooling Data
Cooling Capacity (Btu/h) Cooling Amps (A) Cooling Power (W) EER (Btuh/Watt) Moisture Removal (Pts/h)
Heat Pump Heating Data
Heating Capacity (Btu/h) Heating Amps (A) Heating Power (W) COP (W/W)
Airflow
Indoor CFM (W
et)
@0.3ESP (Hi) Indoor CFM (W
et)
@0.3ESP (Lo) Indoor CFM (Dry)
@0.3ESP (Hi) Indoor CFM (Dry) @0.3ESP (Lo)
LP090HM*
208 230
9,000 9,300
4.1 3.8
820 845
11.0 11.0
2.6 2.6
8,000 8,200
3.4 3.1
690 705
3.4 3.4
240 270 190 230 260 290
220 250
LP120HM*
208 230
11,800 12,000
5.6 5.1
1145 1165
10.3 10.3
3.6 3.6
10,600 10,800
3.4 3.1
1000 1,020
3.1 3.1
310 340 270 300 330 360
290 330
LP150HM*
208 230
14,000 14,100
6.5 7.1
1445 1455
9.7 9.7
4.5 4.5
13,300 13,500
6.0 5.5
1210 1235
3.2 3.2
315 355 275 315 350 390
310 350
LP070HM*
208 230
7,300 7,600
3.0 2.8
600 625
10.9 10.9
2.0 2.0
6,200 6,400
2.6 2.4
520 535
3.5 3.5
195 225 155 185 220 250
180 210
Air Conditioner Performance Data
Heat Pump Performance Data
Page 40
—40—
Model LP070CM* LP090CM* LP120CM* LP150CM* T emperature
Outdoor
Air Return Air Total Wattage Total Wattage Total Wattage Total Wattage
Dry Bulb Wet Bulb Input Input Input
Input
Min Max M in Max Min Max Min Max
Rating Wattage 560 625 785 810 1045 1090 1045 1090
85 590 715 815 900 1050 1180 1080 1190 80 585 720 820 905 1055 1180 1090 1205 75 585 720 820 905 1060 1180 1100 1215
100 70 585 720 820 905 1055 1180 1100 1220
65 590 715 815 900 1050 1180 1095 1215 60 580 710 805 890 1045 1175 1090 1205 55 570 700 795 880 1030 1160 1070 1190 85 560 685 770 855 1000 1125 1025 1140 80 565 690 775 860 1005 1130 1035 1150 75 565 695 780 865 1005 1135 1035 1160
95 70 565 690 775 860 1005 1130 1045 1165
65 560 690 770 855 1000 1125 1040 1160 60 555 680 765 850 990 1120 1030 1150 55 540 670 765 835 980 1105 1020 1135 85 540 660 730 815 950 1070 965 1085 80 540 665 735 820 950 1075 980 1095 75 540 665 735 820 955 1080 990 1105
90 70 540 665 735 820 950 1075 990 1105
65 535 660 730 815 950 1070 990 1100 60 525 660 720 805 940 1060 980 1095 55 520 640 710 795 930 1055 965 1075 85 510 635 690 770 895 1020 915 1025 80 515 640 690 775 900 1020 930 1040 75 520 640 695 780 905 1030 936 1046
85 70 515 640 690 775 900 1020 935 1050
65 510 635 690 770 895 1020 930 1045 60 505 625 680 765 890 1010 925 1035 55 490 615 670 755 880 1000 907 1020 85 485 605 645 730 850 970 860 970 80 490 610 650 735 850 970 870 985 75 490 610 650 735 850 975 880 990
80 70 490 610 650 735 850 970 885 990
65 485 605 645 730 850 970 880 990 60 475 600 635 720 940 960 870 980 55 465 585 625 710 830 950 855 9
65
Cooling Wattage - Air Conditioners
Page 41
—41—
Model LP070HM* LP090HM* LP120HM* LP150HM* T emperature
Outdoor
Air Return Air Total W attage Total Wattage Total Wattage Total Wattage
Dry Bulb Wet Bulb Input Input Input
Input
Min Max Min Max Min Max Min Max
Rating Wattage 600 625 810 850 1120 1145 1430
1460
85 625 705 830 935 1120 1230 1445 1570 80 620 710 835 940 1125 1235 1465 1590 75 620 710 835 940 1130 1240 1475 1600
100 70 620 710 835 940 1125 1240 1475 1600
65 615 705 830 935 1120 1230 1470 1600 60 605 695 820 925 1115 1230 1460 1580 55 595 685 810 915 1100 1210 1440 1562 85 580 670 785 890 1070 1180 1375 1500 80 585 675 790 890 1075 1190 1390 1520 75 590 680 795 890 1075 1190 1410 1530
95 70 585 675 790 890 1075 1190 1410 1530
65 580 670 785 890 1070 1180 1400 1520 60 575 675 780 880 1060 1170 1390 1515 55 560 655 770 865 1050 1160 1370 1495 85 550 640 745 845 1020 1130 1305 1430 80 555 645 750 850 1025 1135 1325 1445 75 555 645 750 850 1025 1135 1335 1460
90 70 555 645 750 850 1025 1125 1340 1460
65 550 640 745 845 1020 1130 1335 1455 60 540 630 735 835 1010 1120 1320 1440 55 530 620 720 825 1000 1110 1260 1420 85 515 610 700 800 970 1080 1240 1360 80 520 610 705 800 975 1085 1260 1380 75 525 615 705 810 975 1085 1265 1390
85 70 520 610 705 800 975 1085 1265 1395
65 515 610 700 800 970 1080 1260 1390 60 510 600 690 790 960 1070 1250 1375 55 500 590 680 775 950 1060 1230 1355 85 485 575 655 755 920 1030 1170 1290 80 490 580 660 760 925 1030 1185 1310 75 490 480 660 760 925 1035 1195 1320
80 70 490 580 660 760 920 1030 1200 1320
65 485 575 655 755 920 1030 1195 1315 60 475 565 650 745 910 1020 1180 1305 55 465 555 635 735 900 1010 1160
1280
Cooling Wattage - Heat Pumps
Page 42
—42—
Cooling change of temperature - Air Conditioners
Room Air Room Air LP070CM LP090CM LP120CM LP150CM
Dry Wet Temperature Across Temperature Across Temperature Across T
emperature Across
Bulb Bulb Indoor Coil ( T) Indoor Coil ( T) Indoor Coil ( T)
Indoor Coil ( T)
Min Max Min Max Min Max Min Max
Rating Btu/h 7000 7600 9000 9300 11700 12000 14300
14600
Rating CFM 185 225 230 260 300 330 315 355
85 1 3 2 6 1 5 1 4 80 8 13 11 14 9 13 8 12
90 75 19 22 19 22 18 22 16 20
70 30 33 28 30 26 30 25 27 80 4 9 7 11 5 10 5 8 75 14 19 15 18 13 18 12 16
85 70 23 27 23 25 21 25 20 23
65 34 36 31 33 29 33 28 30 75 9 14 11 14 9 13 8 12 70 18 21 18 20 15 20 15 18
80 65 26 29 24 27 23 26 21 24
60 35 36 32 33 29 33 29 30 70 12 16 13 16 10 15 10 14 65 18 22 18 21 15 20 15 19
75 60 25 28 23 26 21 25 20 24
55 31 34 28 31 26 30 26 28 65 12 15 12 14 9 13 9 13
70 60 17 20 16 18 13 17 13
17
55 22 24 20 22 18 21 17
21
Model
Room Air Room Air LP070HM* LP090HM* LP120HM* LP150HM*
Dr y Wet Temperature Across Temperature Across Temperature Across T
emperature Across
Bulb Bulb Indoor Coil ( T) Indoor Coil ( T) Indoor Coil ( T) Indoor Coil (
T)
Min Max Mi n Max Min Max Mi n Max
Rating Btu/h 7300 7600 9300 9600 12300 12600 14300
14600
Rating CFM 195 225 240 270 310 340 315 355
8513 26 151 4 80 8 13 11 15 10 13 8 12
90 75 19 22 19 22 18 22 17 20
70 30 33 29 30 26 30 25 28 80 4 9 7 11 5 10 5 9 75 14 19 15 18 14 18 12 16
85 70 23 27 23 25 21 25 21 23
65 33 36 31 33 30 33 28 31 75 9 14 11 15 10 13 8 12 70 18 21 18 20 16 20 16 18
80 65 26 29 24 27 23 26 22 25
60 35 36 32 33 30 33 29 31 70 12 16 13 16 11 15 10 14 65 18 22 18 21 16 20 16 19
75 60 24 28 23 26 21 25 21 24
55 31 34 29 31 26 30 26 29 65 12 15 12 15 10 13 9 13
70 60 17 20 16 18 14 17 13
17
55 22 24 20 22 18 21 18
21
Cooling Change of Temperature - Heat Pumps
Page 43
—43—
Cooling Ampere Chart - Air Conditioners
Cond Inlet Air Te
mperature
Rating Ampere
100
95 90 85 80
Model
Amperage Min Max
6.5 7.1
6.6 8.0
6.2 7.6
5.9 7.2
5.6 6.8
5.3 6.4
Model
Amperage
Min Max
3.6 3.9
3.4 4.0
3.2 3.8
3.1 3.6
2.9 3.4
2.8 3.3
Model
LP070CM LP090CM LP120CM LP150CM Amperage Min Max
2.6 2.9
2.6 2.9
2.4 2.8
2.3 2.7
2.2 2.6
2.1 2.4
Model
Amperage
Min Max
4.8 5.2
5.6 5.6
5.4 5.3
5.2 5.1
4.9 4.8
4.7 4.6
Model
Room Air Room Air LP070HM* LP090HM* LP120HM* LP150HM*
Dry Wet Temperature Across Temperature Across T emperature Across Temperature Across
Bulb Bulb Indoor Coil (T) Indoor Coil (T) Indoor Coil (T)
Indoor Coil (T)
Min Max Min Max Min Max Min Max
Rating Btu/h 6200 6400 8200 8400 10900 11200 13300 13500 Rating CFM 220 250 260 290 330 360 350 390
85 22 24 24 27 27 30 28 30 80 23 24 25 28 28 31 29 31
50 75 24 25 26 29 29 32 30 31
70 26 27 28 30 31 34 32 33 65 26 27 28 30 31 34 32 33 85 19 22 22 24 24 29 27 30 80 20 23 23 25 25 29 28 31
45 75 21 24 24 26 26 30 29 31
70 22 24 24 27 27 31 30 32 65 23 25 25 28 28 32 31 33 85 17 20 20 22 23 27 27 30 80 18 21 21 23 23 28 28 31
40 75 19 22 22 24 24 29 29 31
70 20 23 23 24 25 29 30 32 65 21 24 24 25 26 30 31 33 85 15 17 17 20 21 24 27 29 80 16 18 18 21 22 25 28 30
35 75 17 19 19 22 23 26 29 31
70 18 20 20 23 23 27 30 31 65 19 21 21 24 24 28 31
32
Heating Change of Temperature - Heat Pumps
Cond Inlet Air Te
mperature
Rating Ampere
10
0 95 90 85 80
2
Model LP070HM* LP090HM* LP120HM* LP150HM* Amperage Min Max
.6 2.9
2.6 2.9
2.4 2.8
2.3 2.6
2.1 2.5
2.1 2.3
Model
Amperage
Min Max
3.6 3.9
3.4 4.0
3.2 3.8
3.1 3.6
3.1 3.4
2.9 3.3
Model
Amperage
Min Max
4.8 5.2
5.6 5.5
5.3 5.2
5.0 5.0
4.8 4.7
4.6 4.5
Model
Amperage
Min Max
6.5 7.1
6.6 8.0
6.2 7.6
5.9 7.2
5.6 6.8
5.3 6.4
Cooling Ampere Chart - Heat Pumps
Page 44
—44—
6. TROUBLESHOOTING GUIDE
6.1 OUTSIDE DIMENSIONS
1,066mm (42")
505mm (20")
406mm (16")
406mm (16")
6.2 PIPING SYSTEM
Following is a brief description of the important components and their functions in the refrigeration system. Refer to Figure 61 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle.
MOTOR
COMPRESSOR
OIL
(LIQUID REFRIGERANT)
CAPILLARY TUBE
OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH
SUCTION LIME COOL LOW PRESSURE VAPOR
COOLED AIR
COMPLETE LIQUID BOIL OFF POINT
LIQUID PRESSURE DROP
ROOM AIR HEAT LOAD
VAPOR INLET
HOT DISCHARGED AIR
LIQUID OUTLET
HIGH PRESSURE VAPOR LIQUID PEFRIGERANT LOW PRESSURE VAPOR
ROOM AIR CONDITIONER
EVAPORATOR COILS CONDENSER COILS
CYCLE OF REFRIGERATION
Figure 60
Page 45
—45—
6.3 TROUBLESHOOTING GUIDE
In general, possible trouble is classified in two causes. The one is Starting Failure which is caused from an electrical defect, and the other is Ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application.
Unit is running but cooling is ineffective
Ineffective Cooling
Check of outdoor coil (heat exchanger) & the fan operation.
Check gas leakage.
Repair gas leak.
Replacement of unit if the unit is beyond repair.
Satisfactory operation with temperature difference of inlet & outlet air 44.6~50˚ F (7~10˚ C)
Check heat load increase.
Unexpected residue
Overloaded Circuit
Check of inside gas pressure.
Adjusting of refrigerant charge
Malfunction of compressor
Replacement of compressor
Check of cold air circulation for smooth flow.
Dirty indoor coil (Heat exchanger)
Malfunction of fan
Clogged of air filter
Obstruction at air outlet
Correct above trouble
Check clogging in refrigeration circuit.
Repair clogging in refrigeration circuit.
Page 46
—46—
Fails to Start
Check circuit breaker and fuse.
Gas leakage of feeler bulb of thermostat
Check control switch.
Only fan fails to start.
Improper wiring.
Defect of fan motor capacitor.
Irregular motor resistance ( ). Irregular motor insulation ( ).
Replacement of fan motor
Regular but fails to start
Replacement of compressor (locking of rotor, metal)
Improper thermostat setting
Loose terminal connection.
Improper wiring
Irregular motor resistance ( )
Irregular motor insulation ( )
Replacement of compressor (Motor damaged)
Drop of power voltage.
Check capacitor.
Replacement.
Only compressor fails to start.
Defect of compressor capacitor.
Check power source.
Check control switch setting.
Page 47
—47——47—
COMPLAINT CAUSE REMEDY
Check voltage at outlet. Correct if none. Check voltage to rotary switch. If none, check
power supply cord. Replace cord if circuit is open. Check switch continuity. Refer to wiring diagram
for terminal identification. Replace switch if defective.
Connect wire. Refer to wiring diagram for terminal identification. Repair or replace loose terminal.
Test capacitor. Replace if not within ±10% of manufacturer's rating. Replace if shorted, open, or damaged.
Fan blade hitting shroud or cross flow fan hitting scroll. Realign assembly.
Units using slinger ring condenser fans must have 1/4to 5/16inch clearance to the base. If it is hitting the base, shim up the bottom of the fan motor with mounting screw(s).
Check fan motor bearings; if motor shaft will not rotate, replace the motor.
Check voltage. See limits on this page. If not within limits, call an electrician.
Test capacitor. Check bearings. Does the fan blade rotate freely? If not, replace fan motor.
Pay attention to any change from high speed to low speed. If the speed does not change, replace the motor.
Check grommets; if worn or missing, replace them. If cracked, out of balance, or partially missing,
replace it. If cracked, out of balance, or partially missing,
replace it. Tighten it. If knocking sounds continue when running or
loose, replace the motor. If the motor hums or noise appears to be internal while running, replace motor.
No power Power supply cord
Rotary switch
Wire disconnected or connection loose
Capacitor (Discharge capacitor before testing.)
Will not rotate
Revolves on overload.
Grommets Fan
Turbo fan
Loose set screw Worn bearings
Fan motor will not run.
Fan motor runs intermittently
Fan motor noise.
Page 48
—48—
NAME PLATE RATING MINIMUM MAXIMUM
208/230V 187V 253V
COMPLAINT CAUSE REMEDY
Check voltage. See the limits on the preceding. page. If not within limits, call an electrician.
Check the wire connections, if loose, repair or replace the terminal. If wires are off, refer to wiring diagram for identification, and replace. Check wire locations. If not per wiring diagram, correct.
Check for continuity, refer to the wiring diagram for terminal identification. Replace the switch if circuit is open.
Check the position of knob If not at the coldest setting, advance the knob to this setting and restart unit. Check continuity of the thermostat. Replace thermostat if circuit is open.
Check the capacitor. Replace if not within ±10% of manufacturers rating. Replace if shorted, open, or damaged.
Check the compressor for open circuit or ground. If open or grounded, replace the compressor.
Check the compressor overload, if externally mounted. Replace if open. (If the compressor temperature is high, remove the overload, cool it, and retest.)
Voltage
Wiring
Rotary
Thermostat
Capacitor (Discharge capacitor before servicing.)
Compressor
Overload
Compressor will not run, but fan motor runs.
ROOM AIR CONDITIONER VOLTAGE LIMITS
Page 49
—49—
COMPLAINT CAUSE
REMEDY
Check the voltage. See the limits on the preced­ing page. If not within limits, call an electrician.
Check overload, if externally mounted. Replace if open. (If the compressor temperature is high, remove the overload, cool, and retest.)
If not running, determine the cause. Replace if required.
Remove the cabinet. inspect the interior surface of the condenser; if restricted, clean carefully with a vacuum cleaner (do not damage fins) or brush. Clean the interior base before reassembling.
If condenser fins are closed over a large area on the coil surface, head pressures will increase, causing the compressor to cycle. Straighten the fins or replace the coil. Test capacitor. Check the terminals. If loose, repair or replace. Check the system for restriction. If restricted, clean of replace. Close if open. Determine if the unit is properly sized for the area to be cooled. Check the set screw or clamp. If loose or missing, correct. If the blower or fan is hitting air guide, rearrange the air handling parts. Carefully rearrange tubing not to contact, compressor, shroud, and barrier.
Voltage
Overload
Fan motor
Condenser air flow restriction
Condenser fins (damaged)
Capacitor Wiring Refrigerating system Air filter Exhaust damper door Unit undersized
Cross flow fan
Copper tubing
Compressor cycles on overload.
Insufficient cooling or heating
Excessive noise.
Page 50
—50—
7. SCHEMATIC DIAGRAM
LOCATION
NO.
1 2
3 4
5 6
Q'TY
PER SET
1
LP090CED
4681A20064E 4681A20200A
3H00660C
2H1451G 6323A20006B 5416A30010A 6730A90013B
4681A20064A 4681A20200A
3H00660C
6120AR2194C
6323A20006B
2520UTBK055
6750U-L028A
4681A20064A 4681A20200A
3H00660C 6120AR2194C 6323A20006B
2520UMCK2CA
6750U-L005A
LP120CED
6411A20048M
LP150CED
1 1
1 1
1 1
1
REMARKS
DESCRIPTION
PART NO.
POWER CORD MOTOR
CAPACITOR THERMOSTAT
COMPRESSOR OVERLOAD PROTECTOR
INDOOR OUTDOOR BOX TYPE CAN TYPE
Page 51
51
LOCATION
NO.
1 2
3 4
5 6 7
Q'TY
PER SET
1
LP090HED
4681A20064E 4681A20200A
3H00660C
2H1451G 6323A20006B 6323A20006C 5416A30010A 6730A90013B
4681A20064A 4681A20200A
3H00660C
6120AR2194C
6323A20006B 6323A20006C 5416A90055B 6750A90013C
4681A20064A 4681A20200A
3H00660C 6120AR2194C 6323A20006B 6323A20006C
2520UMCK2CA
6750U-L005A
LP120HED
6411A20048M
LP150HED
1 1
1 1
1 1
1 1
REMARKS
DESCRIPTION
PART NO.
POWER CORD MOTOR
CAPACITOR INDOOR THERMISTOR
OUTDOOR THERMISTOR COMPRESSOR
OVERLOAD PROTECTOR
INDOOR OUTDOOR BOX TYPE CAN TYPE
Page 52
—52—
8. EXPLODED VIEW
CC-1
D
F
E
A B
552113
552116
552112
552114 35211A 552113
352116
352116
352115
352115
352390
146811
152302
359011
753000
W50400
152302-1
435301
249941
W0CZZ
W0CZZ
263230
W6640
249950
238310
261702
354210
546810-1
546810
359011
W48602
549990
130401
554160
554030
753010
349600
135511
567502
135511
249941-1
550140
148000
264110
TEMP/TIME
M O
D E
H
E A
T
H
E A
T
E / S
A V E
E / S
A V
E
F A N
F A N
C O
O L
C O
O L
H
I G H
H
I G
H
L O W
L O W
T I
M E R
T I
M E R
F A
N
T
I
M
E
R
'
F
O
N
O
F F
O
N
O
F F
O
N O F
F
O
N O F
F
268712
249941-3
249941-2
668713
Page 53
—53—
9. REPLACEMENT PARTS LIST
PART NO.
DESCRIPTION
REMARK
LOCATION
NO
.
LP090CM3 LP120CM3 LP120CM5 LP150CM5
A 249951 CONTROL BOX, ASM (INDOOR) 4995A20464S 4995A20463V 4995A20463U 4995A20464S
264110 POWER CORD ASM 6411A20021A 6411A20022E 268714 PCB ASM (MAIN) 6871A10082D 6871A10082C 149410 KNOB ASM 4941A30015B 237200 PANEL ASM, CONTROL 3720A20169A 237204 PANEL, SIDE 3720A20186A 238310 ESCUTCHEON 3831A30008A 263230 THERMISTOR ASM 6323A20003K
263230 THERMISTOR ASM 6323A20006A WOCZZ CAPACITOR, DRAWING (INDOOR) 3H00660C WOCZZ CAPACITOR, DRAWING (OUTDOOR) 2H01451G 6120AR2194D 6120AR2194B
W6640 TERMINAL BLOCK 3H00390A
261704 TRANSFORMER, POWER 6170A20012A
249940 CONTROL BOX ASM, SINGLE 4994A20052A
147900 BARRIER, SINGLE 4790A20033A
135510 COVER ASM (CONTROL) 3551A20062E
B 554160 COMPRESSOR SET 5416A30010A 2520UKLK2BA 2520UMCK2CA
550140 ISOLATOR, COMP 4H00982E
567502 O.L.P 6750A90013B 6750U-L061A 6750U-L005A
C 35211A TUBE ASM, SUCTION 5211A20649D 5211A21365A 5211A20621A
352113 TUBE ASM, DISCHARGE 5211A20650E 5211A20531A 5211A20622A
552111 TUBE ASM, CAPILLARY 5211A20651G 5211A20623D 5211A20623A
552113 TUBE ASM, CONDENSER OUT 5211A30434A 5211A30434A 5211A30434B
552102 TUBE CAPILLARY, BEND 5210A22614A 5210A22614D 5210A21368C
D 147911 BARRIER ASM, INDOOR 4791A10005D 4791A10005A
346810 MOTOR ASM (INDOOR) 4681A20064E 4681A20064A
349600 MOUNT, MOTOR 4960A20026A 4960A20032A
359011 FAN ASM, CROSS FLOW 5901A10027A
349011 DAMPER ASM 4901A30002A
152302 FILTER (MECH), A/C 5230A20016A
E 135312 GRILLE ASM, FRONT 3531A10149C
152302 FILTER (MECH), A/C 5230A20021A
F 135515 COVER ASM, TOP 3551A20197B 3551A20197E 3551A20197F
753000 HEATER, ELECTRIC 5300A20006A 5300A20006C
W50400 GASKET 5040A30032A
546811 MOTOR ASM (OUTDOOR) 4681A20063E 4681A20063A
130413 BASE ASM, WELD 3041A20028B
135500 DRAIN COVER 3550A20102A
349600 MOUNT, MOTOR 4960A20005A
149980 SHROUD 4998A20001B
559010 FAN ASM, AXIAL 5900AR1173A
W48602 CLAMP, SPRING 3H02932B
148000 BRACE 4800A20002A
354210 EVAPORATOR ASM 5421A20114C 5421A20118C 5421A20118A
554030 CONDENSER ASM 5403A20076F 5403A20076A
Page 54
—54—
A 249950 Case Assembly,Control 4995A20824B 4995A20825C 4995A20826D R
249941 Panel,Control 3720A20710A R 138310 Escutcheon 3831A20145A R 268712 PCB Assembly,Display 6871A00085A R 268714 PCB Assembly,Main 6871A00084C R
261702 Transformer ,linear 6170A20012A R 249941-1 Barrier,Indoor 4790A20072A R 249941-2 case,control 4994A20127B R 249941-3 case,control(indoor) 4994A20128A R
135511 Cover 3550A20514A R
668713 PCB Assembly, Sub 6871A00084C R
264110 Power Cord Assembly 6411A20048M R
W0CZZ Capacitor,Film,Box 3H00660C R
W1CZZ-1 Capacitor,Film,Box 2H01451G 6120AR2194C 6120AR2194A R
W6640 Conector,Terminal Block 3H00390A R
B 554160 Compresser 5416A30010A 2520UTBK055 2520UMCK2CA R
550140 Damper Compresser 4H00982E R
567502 Overload Protect 6750A90013B 6750U-L028A 6750U-L005A R
C 552114 Tube Assembly,Discharge 5211A21542A AJR30135701 AJR30135701 R
35211A Tube Assembly,Suction 5211A26009A 5211A26009C 5211A26009C R
352116 Tube Assembly,Evaporator(Out) 5211A21791A 5211A21791B 5211A21791B R
352115 Tube Assembly,Evaporator(IN) 5211A29905A 5211A29905A 5211A29905A R 352115-1 Tube Assembly,Evaporator(IN) 5211A26718A 5210A26718B 5210A26718B R
552113 Tube Assembly,Condenser(Out) 5211A24129A 5211A24129B 5211A24129C R
D 352390 Guide Assembly,Air 5239A10019B 5239A10019A 5239a10019A R
146811 Motor,AC 4681A20064E 4681A20064A 4681A20064A R
349600 Braket,Motor 4960A20026A 4810A20809A 4810A20809A R
359011 Fan Assembly,Cross Flow 5901A20050A R
359001 Damper Assembly 4901A30002C R
152302 Filter,Air 5230A20016A R 152302-1 Cover Assembly,Top(Outdoor) 3551A20224A R
330860 Pan Drain 3086A20011A R
330870 Pan Assembly,Drain 3087A20033A R
E 435301 Grille Discharge 3530A20040B R
152302-1 Filter ,Air 5230A20021A R
F 135515 Cover Assembly,Top(Indoor) 3551A20223A R
753010 Heater Assembly,Electric 5301A20036A 5301A20036B R
753000 Heater Electric 5301A10047A 5301A10047B R
546810 Motor AC 4681A20200A R
130401 Base Assembly,Weld 3041A20028R 3041A20028M R
135511 Cover 3550A20102A R 349600-1 Bracket Motor 4960A20005A R
549990 Shroud Assembly 4999A20004A R
359011 Fan Assembly,Axial 5901A20051A R
W48602 Clamp Spring 3H02932B R
148000 Supporter 4800A20002D R
354210 Evaporator Assembly 5421A20118A 5421A20118C R
554030 Condenser Assembly 5403A20091D 5403A20076B R
PART NO.
DESCRIPTION
REMARK
LOCATION
NO
.
LP090CED LP120CED LP150CED
COOLING ONLY MODELS
Page 55
—55—
A 249950 Case Assembly,Control 4995A20824F 4995A20824A 4995A20824E R
249941 Panel,Control 3720A20710A 3720A20710A R
238310 Escutcheon 3831A20145A 3831A20145A R
268712 PCB Assembly,Display 6871A00085A 6871A00085A R
268714 PCB Assembly,Main 6871A00084A R
261702 Transformer ,linear 6170A20012A R 249941-1 Barrier,Indoor 4790A20072A R 249941-2 case,control 4994A20127A R 249941-3 case,control(indoor) 4994A20128A R
135511 Cover 3550A20514A R
668713 PCB Assembly, Sub 6871A00086A R
264110 Power Cord Assembly 6411A20048M R
W0CZZ Capacitor,Film,Box 3H00660C R
W1CZZ-1 Capacitor,Film,Box 2H01451G 6120AR2194C 6120AR2194A R
W6640 Conector,Terminal Block 3H00390A R
B 554160 Compresser 5416A30010A 5416A90055B 2520UMCK2CA R
550140 Damper Compresser 4H00982E R
567502 Overload Protect 6750A90013B 6750A90013C 6750U-L005A R
C-1 552116 Tube Assembly,Reverse AJR30229001 5211A21792A 5211A21792A R
561410 Solenoid 6141A20006B R
352116 Tube Assembly,Evaporator(Out) 5211A21791C 5211A21791A 5211A21791A R
352115 Tube Assembly,Evaporator(IN) 5211A29905A 5211A29905A 5211A29905A R 352115-1 Tube Assembly,Evaporator(IN) 5211A26718B 5211A26719B 5211A26719B R
552112 Tube Assembly,Condenser(In) 5211A20678A 5210A26718B 5210A26718B R
552113 Tube Assembly,Condenser(Out) AJR30228801 5211A21794A 5211A21794A R
D 352390 Guide Assembly,Air 5239A10019B 5239A10019A 5239A10019A R
146811 Motor,AC 4681A20064E 4681A20064A 4681A20064A R
349600 Braket,Motor 4960A20026A 4810A20809A 4810A20809A R
359011 Fan Assembly,Cross Flow 5901A20050A R
359001 Damper Assembly 4901A30002C R
152302 Filter,Air 5230A20016A R 152302-1 Cover Assembly,Top(outdoor) 3551A20224A R
330860 Pan Drain 3086A20011A R
330870 Pan Assembly,Drain 3087A20033A R
E 435301 Grille Discharge 3530A20040B R
152302-1 Filter ,Air 5230A20021A R
F 135515 Cover Assembly,Top(Indoor) 3551A20223A R
753010 Heater Assembly,Electric 5301A20036A 5301A20036B 5301A20036B R
753000 Heater Electric 5301A10047A 5301A10047B 5301A10047B R
546810 Motor AC 4681A20200A R
130401 Base Assembly,Weld 3041A20028P 3041A20028K 3041A20028K R
135511 Cover 3550A20102A R 349600-1 Bracket Motor 4960A20005A R
549990 Shroud Assembly 4999A20004A R
359011 Fan Assembly,Axial 5901A20051A R
W48602 Clamp Spring 3H02932B R
148000 Supporter 4800A20002D R
354210 Evaporator Assembly 5421A20118C 5421A20118A R
554030 Condenser Assembly 5403A20091D 5403A20076G R
PART NO.
DESCRIPTION
REMARK
LOCATION
NO
.
LP090HED LP120HED LP150HED
HEATPUMP MODELS
Page 56
P/No.: 3828A20308D
April, 2006
Printed in Korea
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