LG LP-F8081CL, LP-F8081HL, LP-F8081ZL Service manual

Page 1

1. Preface

–3–

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

1.1 Safety Precautions

¤ When servicing the unit, set the main SWITCH to OFF and remove the POWER SUPPLY cables. ¤Ł Observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or

damaged by the short circuit.

¤Ø After servicing the unit, make an insulation resistance test to protect the customer from being exposed to

shock hazards.

1.2 Features

¤ Design for cooling and heating ¤ŁSuper energy efficiency ¤ØMicom Control ¤ŒWhisper quiet operation ¤ºRemovable air filter ¤ 3 minute delay circuit ¤ 7 hour timer ¤ 3 step speeds for cooling/heating ¤ Auto Restart

Page 2

1.3 Product Specifications

–4–

POWER SOURCE (ø, V, Hz)

COOLING CAPACITY Btu/h

INPUT W

CURRENT A

HEATING CAPACITY Btu/h

(W)

INPUT W

(W)

CURRENT A

(A)

MAKER

TYPE

COMPRESSOR MODEL

INPUT W CURRENT A CAPACITY Kcal/h

NOISE INDOOR dB(A)

LEVEL(1m) OUTDOOR

AIR INDOOR CMM

VOLUME OUTDOOR

REFRIGERANT R-22 Kg

HEAT INDOOR R/C/FPI

EXCHANGER OUTDOOR R/C/FPI

FAN INDOOR TYPE

OUTDOOR

ROOM TEMPERATURE CONTROL

NET INDOOR Kg

WEIGHT OUTDOOR

DIMENSIONS INDOOR mm

(W × H × D) OUTDOOR

SVC LIQUID Inch

VALVE GAS (mm)

3,380 – 415,50 3,380 – 415,50

71,400 71,400 20,927 20,927

6,900 7,000

12.0 13.0

–

74,000 (8,000)

–

21,680 (8,000)

–

6,500

(8,000)

–

12.5

(12.0)

COPELAND COPELAND

SCROLL SCROLL

ZR94KC – TFD ZR94KC – TFD

6,990 6,990

13.6 13.6

19,732 19,732

56 56 65 65 35 35

104 104

5.9 7.2 3/33/17 3/33/17 2/18/17 2/18/17

SIROCO SIROCO

PROPELLER PROPELLER

MICOM CONTROL MICOM CONTROL

132 132 150 150

1,050 ×1,880 ×495 1,050 ×1,880 ×495

1,000

965 ×370 1,000 ×965 ×370

5/8 5/8

1 1

MODEL

LP-F8081CL

LP-F8081HL LP-F8081ZL

(Including Electric

heater)

Page 3

–5–

1.4 Functions

Indoor Unit

Power Switch ON/OFF

Operation Mode Control

Sensing the room temperature

Controlling the room temperature

Starting Current Control

Sensing Heat Exchanger Temperature

Timer Delay Safety Control

Indoor Fan Speed Control

Operation Indication lamps

Temperature Setting

Airflow Direction Control

Room temperature Display

Timer Control

• Cooling, Soft Dry, Auto, Fan ➔ Cooling Model •

Cooling, Heating, Soft Dry, Fan➔ Heat Pump Model

• Room temperature sensor (Thermistor)

• Maintains the room temperature in accordance with the setting temperature.

• Indoor fan is delayed for 3 sec at the starting.

• Heat exchanger temperature sensor (Thermistor)

• Restarting is inhibited for approx. 3 minutes.

• High, Low, Duct

• Up : up to 30°C

• Down : down to 16°C

• Airflow direction Manual control

• Low, 10° ~ 35°C, Hi

• Off Timer (1, 2, 3....7 hour)

Page 4

–6–

Outdoor Unit

Deice Control

Outdoor Fan Speed Control

Sensing Heat Exchanger Temperature

• De-ice PCB

• One speed

• Heat exchanger temperature sensor (Thermistor)

Page 5

2. Dimensions

–7–

Indoor Unit

Outdoor Unit

268568990

1890

1051

496

130 121

193

951

345

93.8

131

525

109.5

58.5

145.8

93.8

Air Outlet Vent

Air Inlet Vent

Window Display

Earth Screw

700

650

963

930

582

185

125

546

1245

700

260

95 80

Air Outlet Vent

Air Inlet Vent

Page 6

3. Wiring Diagram

Indoor & Outdoor Unit Circuit Diagram

(1) LD-F8081CL

–8–

INDOOR UNIT CIRCUIT DIAGRAM

OR BK BL RD

RY3

CN2

CN3

DISPLAY

PCB ASM

CN1

GN/YL

CONNECT TO OUTDOOR UNIT

WH BK

GN/YL

BL BR

YL BL

CONNECT TO CONTACT "R" "N" OF OUTDOOR TERMINAL BLOCK "Tmo1"

NOTE

BL BK BR OR RD WH YL GN/YL

BLUE BLACK BROWN ORANGE RED WHITE YELLOW GREEN/YELLOW

: : : : : : : :

RY3

MAIN PCB ASM

RY2

FUSE (10A)

RY1

SUB PCB ASM

CAPACITOR

INDOOR

FAN MOTOR

ROOM

EVA

2 3 4

3 2 1

FIELD WIRING

NOTE

1. This product is 3ø,4W,380-415V,50Hz.

2. "Check List" before test run. 1st: Reconfirm the wiring connecting of compressor, outdoor unit motor. 2nd: Fasten the screw of "Terminal Block Tmo1,2" once more.

Tmo1,2 52C 51C 63H CH FMo1,2 Co1,2

TERMINAL BLOCK MAGNETIC CONTACTOR EOCR(COMP.) HIGH PRESSURE SWITCH CRANKCASE HEATER OUTDOOR FAN MOTOR RUN CAPACITOR FOR FAN(OUTDOOR)

NOTE

BLUE

BLACK

BROWN

ORANGE

RED

WHITE

YELLOW

GREEN

GN/YL

GREEN/YELLOW

Tmo1

R S T N

3Ø, 4W

380-415V, 50Hz

POWER SUPPLY

CONNECT TO INDOOR UNIT

Co1

Co2

YLBRORBKYLBROR

FMo2FMo1

52C

L1 L2

1 3 5 31

2 4 6 32

COMP

FUSE(5A)

51C

FUSE(5A)

63H

GN/YL

CONNECT TO INDOOR UNIT

GN/YL

4 5 6

Tmo2

Page 7

–9–

(2) LD-F8081HL/ZL

INDOOR UNIT CIRCUIT DIAGRAM

CAPACITOR

OR BK

INDOOR

FAN MOTOR

RY3 RY2

RY1

SUB PCB ASM

FUSE (10A)

DISPLAY

PCB ASM

MAIN PCB ASM

CN1

CN2

ROOM

EVA

CN3

Tmi

YL BL

3 2 1

CONNECT TO CONTACT "T" "N" OF OUTDOOR TERMINAL BLOCK "A"

Ry3

Ry6

Ry7

BKBKBK

BKWHRD

POWER SUPPLY

3Ø 380~415V

50Hz

L1 L2 L3

T1 T2 T3

1 2 3 4 5 6

5 4

Tmi

CONNECT TO OUTDOOR

(HOUSING ASM)

Option part

DEF TH EH EVA TH ROOM TH

Ry3 Ry6 Ry7 THi

Tmi TP TF

TERMINAL BLOCK(INDOOR) BIMETAL SWITCH FOR HEATER THERMAL FUSE

RELAY FOR COMP RELAY FOR HEATER RELAY FOR HEATING THERMISTOR FOR INDOOR TEMP

THERMISTER FOR DISCHARGE AIR ELECTRIC HEATER THERMISTER FOR EVA TEMP. THERMISTER FOR EVA INDOOR TEMP

NOTE

BK:BLACK BL:BLUE BR:BROWN

YL :YELLOW WH:WHITE

OUTDOOR UNIT WIRING DIAGRAM

RD RD RD

R S T N

POWER SUPPLY 3ø,380-415V,50Hz TERMINAL(4P)

CRANKCASE HEATER

FUSE (250V, 5A)

F1,2

RUN CAPACITOR FOR FMo

OUTDOOR FAN MOTOR

FMo

GN/YL

YLBRORBKYLBROR

FMo

49FMo

63H2

BK BK

WH RD RD

63H1

52C

FMo

49FMo

D.P C TH 20SV 49FMo

BKWHRD

COMP

DEICER PCB THERMISTOR FOR PIPE TEMP.(OUTDOOR) REVERSING COIL INERNAL T.P FOR FMo

BK BK

1 3 5 31 A

2 4 6 32 B

A B

52F1 63H1 63H2 49C

3.P.D

S T

WH WH

BK WH BK

20SV

RELAY FOR FMo HIGH PRESSURE SWITCH HIGH PRESSURE SWITCH FOR HEATING INTERNAL O.L.P FOR COMP.

BL BL

NOTE

BL BK BR OR

D.P

52F1

1 2 3 4 5 6 7 8

BLUE

BLACK

BROWN

ORANGE

TM 52C

3.P.D

1 2 3 4 5 6

C TH

BR BL BR BL

GN/YL

NO NC NO

RED

WHITE

YELLOW

GN/YL : GREEN/YELLOW

MAIN TERMINAL BLOCK MAGNETIC CONTACTOR 3 PHASE DETECTOR

Page 8

– 10 –

4. OPERATION DETAILS

(1) The function of main control

1. Time Delay Safety Control

• 3min

...

The compressor is ceased for 3 minutes to balance the pressure in the refrigeration cycle.

(Protection of compressor)

• 3sec

...

The indoor fan is ceased for 1~3 seconds to prevent relay noise. (Protection of fan relay and micro chip)

• 1min

...

The 4-way valve is ceased for 30 sec. to prevent the refrigerant-gas abnormal noise when the Heating operation is OFF or switched to the other operation mode.

2. Cooling Mode Operation

• When selecting the Cooling( ) Mode Operation, the unit will operate according to the setting by the controller and the operation diagram is as following

Intake Air temp.

Setting Temp. +1°C

(Compressor ON)

Setting Temp. -1°C

(Compressor OFF)

Indoor Fan Speed

Selecting

fan speed

Selecting

fan speed

Selecting

fan speed

Selecting

fan speed

Selecting

fan speed

3 minutes 3 minutes

Compressor ON OFF ON OFF ON

Page 9

– 11 –

3. Auto Operation (Cooling Model only)

ƒUThe operation procedure is as following.

ƒƒUU

Auto Operation for Cooling

Press Start/Stop Button

Select Auto Operation Mode

Check the Room temperature

Operation Condition Intake-air Temperature Setting temperature Fan speed

Over 26°C 25°C

Over 24°C~below 25.5°C Intake air -1.0°C Over 22°C~below 23.5°C Intake air -0.5°C

below 21.5°C Intake air Temperature(18°C, MAX)

When Switch to

Auto Operation

Controlled

by Fuzzy logic

Intake Air Temp.

Indoor Fan Speed

Compressor ON OFF

Fuzzy Speed

ON OFF

Setting Temp. +1°C

(Compressor ON)

Setting Temp. -1°C

(Compressor OFF)

3 minutes 3 minutes

Page 10

– 12 –

4. Heating Mode Operation

The unit will operate according to the setting by the remote controller and the operation diagram is shown as following.

Intake Air Temp.

Setting Temp.

(Compressor ON)

Setting Temp. -1°C

Indoor Fan Speed

Compressor

Electric Heater(Option)

OFF ON OFF OFFOFF ON OFF

OFF

LOW

Hot

Start

minimum

10sec.

minimum

1min

minimum

10sec.

OFF

A A

OFFLOW LOW

Setting Temp. +1°C (Compressor OFF)

Selecting

fan speed

Selecting

fan speed

• A point: The indoor pipe temperature to be less then 35°C or Discharge air Temperature to be less than 29°C. The indoor fan operates for minimum 10sec. even if the indoor pipe temperature falls lower than35°C or the discharge air Temperature falls lower than 29°C.

Low(V)Stop(VI)

39˚C

Discharge Air Temp.

Indoor Pipe Temp.

34˚C

28˚C 26˚C

Selecting Fan Speed(IV)

Low(II)Stop(I)

(Hot-Start Operating)

Heating Start

(Hot-Start Release Point)

Selecting Fan Speed(III)

¡ During heating operation, the operating procedure of the indoor fan is as the following.

Step Indoor fan speed Pipe temp. Air discharge temp.

¥ Off ≤28°C(Hot start operating) – ¥– Low ≥28°C <39°C ¥† Selecting speed ≥28°C ≥39°C ¥‡ Selecting speed ≥28°C >34°C ¥· Low ≥26°C ≤34°C ¥ Off ≤26°C –

Page 11

– 13 –

5. Hot-Start Control

• The indoor fan stops until the evaporator piping temperature will be reached to 28°C.

• During heating operation, if piping temperatures fall below 26°C fan stops.

• The operation diagram is as following.

6. Defrost Control

• Defrost operation is controlled by timer and sensing temperature of outdoor pipe.

• The first defrost starts only when the outdoor pipe temperature falls below -6°C after 45 minutes passed from starting of heating operation and more than.

• Defrost ends after 10 minutes pass from starting of defrost operation or when the outdoor pipe temperature rises over 12°C even if before 10 minutes.

• The second defrost starts only when the outdoor pipe temperature falls below -6°C after 45 minutes pass from ending of the first defrost and more than.

INDOOR PIPE

TEMP.

INDOOR FAN

SPEED

Selecting

fan speed

OFF OFFLOW

1min

Maximum

COMPRESSOR ON

28°C

26°C

More than 45 minutes of

heating operation

Outdoor Pipe Temp.

Indoor Fan

Compressor 4-Way Valve

ON ON

OFF

HOT-

START

ON OFF OFFON

12°C

(Defrost OFF)

-6°C

(Defrost ON)

Within

10minutes

Defrost

More than 45 minutes of

heating operation

Less than 5 minutes

Page 12

9. Child Lock function

This function is to operate Air conditioner only by Remocon. The procedure is as the following 1st: Press the 2 buttons of the temperature control simultaneously, to raise-to lower on the Display Panel of the

product for more 3 seconds.

2nd: The buzzer sounds and then the window of Display Panel shows

LLOOCC

(LOC) mark. 3rd: To release this function, the reverse again the operating procedure could be done. ¡ During this function is operating, any buttons of Display Panel don't work. But it is possible to operate with

Remote controller.

10. Off Timer Function

This function is to set the time of stopping the unit operation. The procedure is as the following.

1st: Press the timer set button on the Remocon. 2nd:

The buzzer sounds and then the display window shows the Off-Time to be set as 1:00¡

...

¡ 7:00 ¡ 0:00.

- The Off-Time is shifted as the following by each press.

- If you select '0:00', the Off-Timer function will be cancelled.

- During Off-Timer Operation, if you repress the timer set button, the rest time will be displayed.

– 14 –

8. Protection of the evaporator pipe from frosting

• Compressor and outdoor fan stop when indoor pipe temperature is below -2°C and restart at the pipe temperature is above 12°C.

7. Soft Dry Operation Mode

• During Soft Dry Operation, the compressor ON temperature is the setting temperature plus 2°C, the compressor OFF temperature is the setting temperature minus 1°C.

• When the room temperature rises over the compressor ON temperature, the operation mode is switched to the Cooling mode.

• When the room temperature falls between the compressor ON temperature and OFF temperature, the operation mode is switched to the Soft Dry Operation.

• The operation diagram is shown below.

Intake Air Temp.

Indoor Fan Speed

LOW

Selecting

fan speed

Selecting

fan speed

LOW LOW LOW LOW

Compressor OFFON ONON OFF OFF ON

LOW

OFF

Setting Temp. +2°C

(Compressor ON)

Setting Temp. -1°C

(Compresso OFF)

Operation

Cooling

operation

Dry operation

3 min. 3 min.

10 min.

maximum

7 min.

maximum

10 min.

1:00 2:00 3:00 4:00 5:00 6:00 7:00 0:00

Page 13

11. Alarm mode display / only displayed while operating.

CCHH 00

: The sensor for sensing room temperature is open or short.

CCHH 11

: The sensor for sensing piping temperature of evaporator is open or short.

12. Function for test operation.

This function shall be operated while the set not operating and start while set temperature set button(▼) down and start/stop buttons pressing continuously for 3 seconds. If you press start/stop button continuously for 3 seconds while set temp down button pressing once more test

operation and the set shall be stopped. After test operation operating and 18 minutes, test operation and the set shall be stopped. If you press start/stop button while test operation operating, test operation shall be stopped and the set shall

start. When test operation operating, the display of

8888::8888

shall be shifted to tESt

4-way valve is always off when test operation. Fan speed is high, air purifying system and auto air flow operations are off when test operation.

Regardless of outside temperature, the set operates when test operation. All but start/stop and air purifying system buttons cannot be set.

13. Function of changing set temperature when re-operation after stop.

Heating operation is set to the previous set temperature when re-operation after stop. Cooling operation is set to the previous set temperature when re-operation with start/stop button.

1.Operation mode. Cooling/soft dry mode → Cooling mode

Heating mode → Heating mode

2. Setting the set temperature when cooling operation.

Room temperature > Set temperature: to be set to the previous set temperature. Room temperature ≤ Set temperature a) Room temperature ≥ 26°C: to be set to 24°C b) 22°C ≤ Room temperature ≤ 25°C: to be set to 21°C c) Room temperature ≤ 21°C:to be set to -1°C less than room temperature.

3. Setting the set temperature when heating operation.

Set the previous set temperature when stopped.

14. Auto Restart

In case the power comes on again a power failure, Auto Restarting Operation is the function to operate procedures automatically to the previous operating conditions.

– 15 –

Page 14

5-1.

Installation of Indoor, Outdoor unit

1) Selection of the best location ➀ Indoor unit

• There should not be any heat source or steam

near the unit.

• There should not be any obstacles to prevent the

air circulation.

• A place where air circulation in the room will be

good.

• A place where drainage can be easily obtained.

• A place where noise prevention is taken into con-

sideration.

• Do not install the unit near the door way.

• Ensure the spaces indicated by arrows from the

wall, ceiling, fence, or other obstacles.

➁ Outdoor unit

• If an awning is built over the unit to prevent direct

sunlight or rain exposure, be careful that heat radiation from the condenser is not restricted.

• There should not be any animals or plants which

could be affected by discharged hot air.

• Ensure the space indicated by arrows from the

wall, ceiling, fence, or other obstacles.

–16–

5. Installation

5cm

Indoor unit

Outdoor unit

50cm

150cm

5cm

40cm

100cm

➂ Piping length and the elevation

1" 5/8" 50 35

80K

(Btu/h)

PIPE SIZE

MODEL

GAS SIDE LIQUID SIDE

Max.

Length

A (m)

Max.

Elevation

B (m)

Page 15

–17–

2) Indoor Unit installation

➀ The mounting floor should be strong and solid

enough to prevent it from vibration.

➁ Drill the piping hole with 70mm diameter hole-

core drill at either the right or the left of indoor unit. The hole should be sightly slant to the outdoor side.

3) Outdoor unit Installation

➀ Install the outdoor unit on the concrete or any

solid base securely and horizontally.

➁ If there is any vibration transmitted to the build-

ing, mount the rubber underneath the outdoor unit.

4) Refrigerant amount

Before shipment, this air conditioner is filled with the rated amount of refrigerant including additional amount required for air-purging, subject to 5m piping length. (The rated amount of refrigerant is indicated on the name plate.) But when the piping length exceeds 5 meters, additional charge is required according to the following table.

(Unit: g)

Example) 72K~80K In case of 10m long pipe(one-way), the amount of refrigerant to be replenished is:

(10 - 5) × 80 = 400g

200mm

70mm

90mm

Wall

Core Drill

MODEL

80K

REFRIGERANT CHARGE

80 per 1m

Page 16

–18–

5-2. Installation Method

1) Procedure

No. Installation works Descriptions

1 Preparation of tools and installation parts Preparation of installation 2 Flaring the pipes To insert the flare nuts, mounted on the

connection parts of both indoor and

outdoor unit, onto the copper pipes. 3 Pipe bending To reduce the flow resistance of refrigerant. 4 Connection of installation parts Connection of long piping

(elbows, socket etc) 5 Tighten the flare nut (outdoor) Connecting the pipings of the outdoor unit. 6 Blowing the pipings To remove dust and scale in working. 7 Tighten the flare nut (indoor) Connecting the pipings of the indoor unit. 8 Check a gas-leakage of the connecting

part of the pipings. 9 Air purging of the piping and indoor unit The air which contains moisture and which

remains in the refrigeration cycle may cause a malfunction on the compressor

10 Open the 3-way (liquid side) and

3-way (gas side) valves.

1 1 Form the pipings To prevent heat loss and sweat 12 Checking the drainage (indoor unit) To ensure if water flow drain hose of indoor unit. 13 Connecting the cable between outdoor Preparation of the operating

and indoor unit 14 Connecting the main cable to outdoor unit 15 Supply the power to the crankcase heater To prevent the liquid back to the compressor.

(Before the operating the unit) (Heat pump only) 16 Cooling operation

(Use the remote control or display of the

indoor unit)

Page 17

–19–

2) Preparation of installation parts and tools

No. Installation Parts, Tools Use

1 Pipe cutter (MAX 35mm Copper pipe) Cutting the pipings 2 Remear Remove burrs from cut edges of pipes. 3 Wrench (H5, H4 hexagonal wrench) To open the service valve 4 Pipe bender Bending the pipings 5 Leak detector Check a gas-leakage of connecting part

of the pipings 6 Manifold gauge To measure the pressure, to charge the refrigerant 7 Charge-nipple To connect the bombe 8 Vacuum pump To remove the air in the pipe. 9 Charge cylinder balance To measure the refrigerant amount

10 Bombe (Freon-22) Gas charge

Air purge

Cleaning the pipe

11 Spanner To tighten the connecting parts of the pipings 12 Monkey spanner 13 Driver( , ) 14 Benchi (150mm) Cutting the wires 15 Tapeline To measure the length 16 Core drill To make holes through the concrete wall and blocks 17 Voltmeter, Amperemeter, Clampmeter To measure the current and voltage 18 Insulation resistance tester To measure the insulation resistance 19 Glass thermometer

To measure the intake and outlet air temperature of the indoor unit

20 Copper tubes To use the connecting pipings 21 Insulation material To cover the connecting pipings 22 Tape To finish the connecting pipings 23 Electrical Leakage Breaker To shut off the main power 24 Cable To connect the cable from outdoor unit to indoor unit 27 Drain hose sockets, elbows To remote the condensing water

Page 18

–20–

➀ Cut the pipes and the cable

• Use the accessory piping kit or the pipes purchased locally.

• Measure the distance between the indoor and the outdoor unit.

• Cut the pipes a little longer than measured distance.

• Cut the cable 1.5m longer than the pipe length.

➁ Remove burrs.

• Remove burrs from cut edges of pipes.

• Turn the pipe end down to avoid the metal powder entering the pipe.

Caution:

If burrs are not removed, they may cause a gas leakage.

2) Connection of piping

➀ Move the indoor tubing and drain hose to the hole

• Remove tubing holder and pull the tubing out of the chassis.

➁ Replace the tubing holder into original position ➂ Route the tubing and the drain hose staight backwards. ➃ Insert the connecting cable into the indoor unit through the hole.

• Do not connect the cable to the indoor unit

• Make a small loop with the cable for easy connection later.

➄ Tape the tubing and the connecting cable. ➅ Indoor unit installation. ➆ Connecting the pipings to the indoor unit.

• Align the center of the pipings and suffciently tighten the flare nut with fingers.

• Finally, tighten the flare nut with troque wrench until the wrench clicks. When tightening the flare nut with troque wrench, ensure the direction for tightening follows the arrow on the wrench.

90°

Pipe cutter

Slanted Rough

Pipe

Point down

Reamer

5-3. Piping of Indoor Unit

1) Preparation of piping

Page 19

–21–

3) Precautions in bending

➀

If it is necessary to bend or stretch the tubing, use the spring which is attached to the tubing in

stead of pipe bender.

• Please make a careful notice to make a smooth line.

• Hold the tubing with your two hands closely and then bend or stretch it slowly not to make any crack.

• Remember that the radius (R) should not exceed 70mm (Refer to Fig. 1)

➁ Do not repeat the bending process to prevent the

tubing from cracking or crushing.

➂ Keep in mind that the bending part should not be

cracked and make the radius (R) as long as possible (Refer to Fig. 2)`

Spring

R70mm

(Fig. 1)

(Fig. 2)

5-4. Connecting Piping to Outdoor Unit

1) Connecting pipings to the outdoor unit

➀ Upon connecting 4-way valves, please weld connecting pipes using elbows instead of connecting pipes with

flare nuts.

5-5. Connecting the Cable

➀ Open the control board cover from the outdoor unit by

removing the screws.

➁

Connect wires to the terminals on the control board individually and secure the cables onto the control

board with clamp.

Page 20

MODEL Circuit breaker capacity

80K

50A

(BTU/h)

–22–

5-6. Power Supply and Wiring

Voltage

Time

Starting point

Power source voltage working voltage

Starting voltage

The unit is completely wired internally at the factory according to general rule of electrical technology, but local rules, if they are required, should be complied with.

1) Power Supply

Power source must fulfill the following conditions:

¤ The working voltage should be higher than

90% and lower than 110% of the rated voltage marked on the name plate.

¤Ł The starting voltage should be higher than

85% of the rated voltage marked on the name plate.

¤Ł Provide a recognized circuit breaker as below

between power source and unit. A disconnection device to adequately disconnect all supply lines must be fitted. (for service operations)

¤Ø The screws which fasten the wiring in the cas-

ing of electrical fittings are liable to come loose from vibrations to which the unit is subjected during the course of transportation. Check them and make sure that they are all tightly fastened. (If they are loose, it could give rise to burn-out of the wires.)

¤ŒSee to it that the starting voltage is maintained

at more than 90 percent of the rated voltage marked on the name plate.

¤ºThe following troubles would be caused by volt-

age drop-down. Vibration of a magnetic switch, damage on the contact point there of, fuse breaking, disturbance to the normal function of a overload protection device.

2) Wiring

After the confirmation of the above conditions, prepare the wiring as follows:

¤ Use the power supply cord(Rubber insula-

tion, type Ho7RNF approved by HAR or SAA) suitable for the product's electriccal capacity.

MODEL

80K

(BTU/h)

VOLTS

Conductor

cross-sectional

area

450/ 750V 5.5mm

Page 21

–23–

5-7. Air Purging of the Piping and Indoor Unit

No leakage found leakage found

leakage ceased

leakage persists

The air which contains moisture and which remains in the Refrigeration cycle may cause a malfunction on the compressor.

¤ Remove the caps from the 4-way(liquid side)

and 4-way(gas side) valves.

¤Ł Remove the service-port cap from the 3-way

(gas side) valve.

¤ØTo open the valve, turn the valve stem of 3-way

(liquid side) valve counter-clockwise approx. 90° and hold it there for ten seconds, then close it.

¤ŒCheck a gas-leakage of the connecting portion

of the pipings.

¤ºTo open 3-way(liquid side) valve

again, turn the valve stem counterclockwise until it stops.

¤ To purge the air, push the pin on the service port

of 3-way(gas side) valve for three seconds using with a hexagonal wrench and set it free for one minute.

• Repeat this three times.

Result

• Re-tighten the connecting portion with torque wrenches.

Outdoor unit

Service port cap

Hexagonal wrench

3-way valve cap (gas side)

3-way valve cap (liquid side)

To indoor unit

Page 22

–24–

Set the both 3-way(liquid side) and 3-way(gas side) valves to open position with the Hexagonal wrench for the unit operation.

Checking a gas leakage for the left piping

• Connect the manifold gauge to the service port of 3-way(gas side) valve. Measure the pressure.

• Keep it for 5 - 10 minutes. Ensure if the pressure indicated on the gauge is as same as that of measured at first time.

CLOSE CLOSE

Closed

Indoor unit

Outdoor unit

Liquid side

Gas side

Page 23

–25–

5-8. Checking the Drainage and Form the Piping

1) Checking the Drainage

¤ Remove the inlet grille.

¤Ł Check the drainage.

• Pour a glass of water into the drain pan.

• Ensure if water flows drain hose of indoor unit.

Page 24

–26–

2) Form the Piping

¤ Wrap the connecting portion of indoor unit with the

insulation material and secure it with two Plastic Bands. (for the right piping)

• If you connect an additional drain hose, the end of the drain-outlet should be kept distance from the ground. (Do not dip it into water, and fix it on the wall to avoid swinging in the wind.)

¤ŁTape the Piping, and Connecting Cable from down

to up.

¤ØForm the piping gathered by taping along the exteri-

or wall and fix it onto the wall by saddle or equivalent.

¤ Tape the piping and connecting cable from down to

up.

¤Ł In order to prevent water from entering the room,

form a trap and tape the piping.

¤Ø Fix the piping onto the wall with saddle or bracket.

In case of the outdoor unit is installed below position of the indoor unit.

In case of the outdoor unit is installed upper position of the indoor unit.

Main cable Gas side piping

Connecting Cable (For heater)

Connecting Cable

Tube PE Foam

Trap is required to prevent the electrical parts from entering the water.

Seal a small opening around the piping with gum type sealer.

Trap

Page 25

–27–

5-9 Final Check and Test Run

After installing the unit, perform the final check and running test as follows: Final check points

¤ Is the unit securely mounted? ¤ŁIs the installation location adequate? ¤ØIs the water piping work adequately and without

leakage?

¤ŒAre trapped drain lines installed at condensate

drain connections?

¤ºHas the refrigeration cooling cycle been kept

sealed?

¤ Is the electrical wiring adequate and are the

screws tightened on terminals?

After the above final checkings, prepare the running test as follows:

¤ Connect compound gauges to the check joints at

discharge and suction sides of the compressor.

¤ŁTurn all switches "OFF". ¤ØTurn the main switch "ON".

Running test should be accomplished as follows:

¤ Set operation switch at "FAN" and the fan will

start. Check to ensure that the fan sounds normal.

¤ŁNext, set it at "COOL" and the compressor will

start. Check to ensure that the compressor sounds normal.

¤ØCheck discharge and suction pressure on the

compound gauges.

¤ŒCheck working voltage, phase balance and run-

ning current.

¤ºCheck to ensure that the thermistor functions

properly.

¤ Check to ensure that the high pressure control

switch functions correctly.

Page 26

–28–

5-10 Installation Check List

1. Is the unit securely mounted and levelled?

Space for Evaporator Air Flow Space for Condenser Air Flow Space for Maintenance Work Noise and Vibration Appearance

2. Is electrical wiring system adequate?

Wire Size Tightened Connection Switch Size Operation Control Devices Fuse Size Safety Devices Voltage Hz

3. Does the refrigerant piping work adequately?

Pipe Size Leakage Insulation Refrigerant Charge Vibration Trap

4. Does the duct work adequately?

Pipe Size Sound-proof Insulation Vibration-Proof

Vibration

5. Are the condensate drain lines properly arranged?

Trap Drain Ditch

6. Are the service valves opened?

Page 27

–29–

5-11 Running Test and Maintenance Record

JOB NUMBER: POWER SUPPLY : Main Power_______ V, ________ Hz

Accessory Attached : CUSTOMER'S NAME AND ADDRESS : (PHONE NO.: ) INSTALLED BY: DATE: START UP BY: DATE:

❐ 1. Does the operation switch function properly? ❐ 2. Is the rotating direction of the evaporator fan correct? ❐ 3. Is the rotating direction of the condenser fan correct? ❐ 4. Is the evaporator airflow sufficient? ❐ 5. Are there any abnormal sounds? ❐ 6. Has the unit been operated at least twenty (20) minutes? ❐ 7. Check indoor temperatures :

Inlet : DB __________ °C, WB _______________°C Outlet : DB __________ °C, WB _______________°C

❐ 8. Check outdoor temperatures :

Inlet : DB __________ °C Outlet : DB __________ °C

❐ 9. Check pressures :

Discharge pressure:________kg/cm

Suction pressure: ____kg/cm

❐ 10. Check voltage :

Rated voltage:________ V Operating voltage:R-S __________ V, S-T _____ V, T-R ______V. Starting voltage: _____ V (≥0.85 x Rated Voltage) Phase unbalance : 1-V/V mean = ______ (-0.03 ≤ Imbalance ≤ +0.03)

❐ 11. Check running current:

packaged air conditioner: ____ A

❐ 12. Do the control devices function properly? ❐ 13. Do the protective devices function correctly? ❐ 14. Is the refrigerant charge adequate? ❐ 15. Is the drain line draining properly? ❐ 16. Is the air filter clean? ❐ 17. Are the evaporator coil and condenser coil clean? ❐ 18. Are all cabinet panels fixed? ❐ 19. Are all cabinet panels free from rattles?

Indoor Unit Outdoor Unit

Model ( V, Hz) ( V, Hz)

Production No.

Page 28

6. Operation

–30–

Display

START/STOP BUTTON

Operation starts when this button is pressed and stops when the button is pressed again.

¤Ł

OPERATION MODE SELECTION BUTTON

Used to select the operation Mode.

¤Ø

ROOM TEMPERATURE SETTING BUTTONS

Used to select the room temperature.

¤Œ

INDOOR FAN SPEED SELECTION

Used to select fan speed in three steps-low, med, high.

¤º

FAN OPERATION LAMP

COOLING OPERATION LAMP

SOFT DRY OPERATION LAMP

HEATING OPERATION LAMP

DEFROST OPERATION LAMP

AUTO OPERATION LAMP

¤æ

DUCT AIR FLOW LAMP(OPTION)

OUTDOOR UNIT OPERATION LAMP

TIMER SETTING BUTTON (OPERATION STOPS AT ON)

TIMER OPEATION LAMP

¤ı

ELECTRIC HEATER OPERATION LAMP

ELECTRIC HEATER OPERATION BUTTON (OPTION)

DUCT

OUT DOOR

ROOM TEMP. SET TEMP.

DUCT

OUT DOOR

ROOM TEMP. SET TEMP.

147

2 3 4 12

65 11713

2 3 4 12 116 8 9

65 14 11 15

Page 29

–31–

Works Shaft position Shaft position Service port

Shipping Closed Closed Closed

(with valve cap) (with valve cap) (with valve cap)

1. Air purging Open Closed Open (Installation) (counter-clockwise) (clockwise) (push-pin)

Operation Open Open Closed

(with valve cap) (with valve cap)

2. Pumping down Open Open Open

(transferring) (clockwise) (counter (connected

-clockwise) manifold gauge)

3. Evacuation Open Open Open

(Servicing) (with charging

cylinder)

4. Gas charging Open Open Open

(Servicing) (with charging

cylinder)

5. Pressure check Open Open Open

(Servicing) (with charging

cylinder)

6. Gas releasing Open Open Open

(Servicing) (with charging

cylinder)

3-Way Valve (Liquid Side) 3-Way Valve (Gas Side)

7. 3-Way Valve

Valve cap

Open position

Flare nut

To piping connection

To outdoor unit

Closed position

Service

cap

port

Service port

Flare nut

To piping connection

Valve cap

Open position Closed position

Service port

To outdoor unit

cap

Service port

Page 30

–32–

Gas side

Liquid side

Indoor unit

Outdoor unit

Closed

3-way valve

Closed

3-way valve

7.1 Air purging

Required tools: hexagonal wrench, adjustable wrench, torque wrench, and gas leak detector. The additional gas for air purging has been charged in the outdoor unit. However, if the flare connections have not been done correctly and there gas leaks, a gas cylinder and the charge set will be needed. The air in the indoor unit and in the piping must be purged. If air remains in the refrigeration pipes, it will affect the compressor, reduce cooling capacity, and can lead to a malfunction.

• Procedure

¤ Recheck the piping connections. ¤ŁOpen the valve stem of the 3-way(liquid side) valve

counterclockwise approximately 90°, wait 10 seconds, and then set it to closed position.

- Be sure to use a hexagonal wrench to operate the valve stem.

¤ØCheck for gas leakage.

-Check the flare connections for gas leakage.

¤ŒPurge the air from the system.

- Set the 3-way(liquid side) valve to the open position and remove the cap from the 3-way(gas side) valve's service port.

- Using the hexagonal wrench to press the valve core pin, discharge for three seconds and then wait for one minute. Repeat this three times.

¤ºUse torque wrench to tighten the service port nut. ¤ Set the 3-way (gas side) valve to the back seat.

¤ Mount the valve stem nuts to the 3-way (liquid

side)valve and 3-way (gas side) valves.

¤ Check for gas leakage.

• At this time, especially check for gas leakage from the 3-way (liquid side) valve and 3-way (gas side) valve's stem nuts, and from the service port nut.

Caution

If gas leakage is discovered in step

¤¤ØØ

above,

take the following measures:

If the gas leaks stop when the piping connections are tightened further, continue working from step ¤Œ. If the gas leaks do not stop when the connections are

retightened, repair the location of the leak, discharge all of the gas through the service port, and then recharge with the specified amount of gas from a gas cylinder.

Service port nut. Be sure, using a torque wrench to tighten the service port nut (after using the service port), so that it prevents the

gas leakage from the refrigeration cycle.

Page 31

7.2 Pump down

• Procedure

¤ Confirm that both 3-way(liquid side) and 3-

way(gas side) valves are set to the open position.

• Remove the valve stem caps and confirm that the valve stems are in the raised position.

• Be sure to use a hexagonal wrench to operate the valve stems.

¤ŁOperate the unit for 10 to 15 minutes.

¤ØStop operation and wait for 3 minutes, then

connect the charge set to the service port of the 3-way (gas side) valve.

- Connect the charge hose with the push pin to the service port.

¤ŒAir purging of the charge hose.

• Open the low-pressure valve on the charge equipment slightly to purge air from the charge hose.

¤ºSet the 3-way(liquid side) valve to the closed

position.

¤ Operate the air conditioner at the cooling cycle

and stop it when the gauge indicates 1 kg/cm2g

¤ Immediately set the 3-way(gas side) valve to the

closed position.

- Do this quickly so that the gauge ends up indicating 3 to 5kg/cm2g.

¤ Disconnect the charge set, and mount the

3-way(liquid side) and 3-way(gas side) valve's stem nuts and the service port nut.

- Use torque wrench to tighten the service port nut.

- Be sure to check gas leakage.

CLOSECLOSE

Purge the air

Gas side

Liquid side

Indoor unit

Outdoor unit

Closed

Open

3-Way valve

–33–

Page 32

1) Re-airpurging

(Re-installation)

• Procedure

¤ Confirm that both the 3-way (liquid side) valve

and the 3-way(gas side) valve are set to the closed position.

¤ŁConnect the charge set and a gas cylinder to the

service port of the 3-way(gas side) valve.

• Leave the valve on the gas cylinder closed.

¤ØAir purging.

• Open the valves on the gas cylinder and the charge set. Purge the air by loosening the flare nut on the 3-way(liquid side) valve approximately 45° for 3 seconds then closing it for 1 minute; repeat 3 times.

• After purging the air, use a torque wrench to tighten the flare nut on liquid side valve.

¤ŒCheck gas leakage.

• Check the flare connections for gas leakage.

¤ºDischarge the refrigerant.

• Close the valve on the gas cylinder and discharge the refrigerant until the gauge indicates 3 to 5kg/cm2g

¤ Disconnect the charge set and the gas cylinder,

and set the 3-way(liquid side) and 3-way(gas side) valves to the open position.

• Be sure to use a hexagonal wrench to operate the valve stems.

Mount the valve stem nuts and the service port nut.

• Use torque wrench to tighten the service port nut.

• Be sure to check gas leakage.

OPEN

R22

Gas side

Gas cylinder

Liquid side

Indoor unit

Outdoor unit

Closed

3-Way valve

Closed 3-Way valve

–34–

Page 33

2) Balance refrigerant of the 3-way(liquid side), 3-way(gas side) valves

(Gas leakage)

• Procedure

¤ Confirm that both the liquid side and gas side valves are set to the back seat.

¤ŁConnect the charge set to the 3-way(gas side) valve's port.

• Leave the valve on the charge set closed.

• Connect the charge hose with the push pin to the service port.

¤Ø Open the valve (Lo side) on the charge set and discharge the refrigerant until the gauge indicates 0 kg/cm

- If there is no air in the refrigerant cycle (the pressure when the air conditioner is not running is higher than 1 kg/cm2g), discharge the refrigerant until the gauge indicates 0.5 to 1 kg/cm2g. In case of this, it will not be necessary to apply an evacuation.

- Discharge the refrigerant gradually; if it is discharged too suddenly, the refrigeration oil will also be discharged.

OPEN

Gas side

Liquid side

Indoor unit

Outdoor unit

Open

3-Way valve

–35–

Page 34

7.3 Evacuation

(All amount of refrigerant leaked)

• Procedure

¤ Connect the vacuum pump to the center hose of charge set.

¤ŁEvacuation for approximately one hour.

- Confirm that the gauge needle has moved toward -76cmHg (vacuum of 4 mmHg or less).

¤ØClose the valve (Lo side) on the charge set, turn off the vacuum pump, and confirm that the gauge needle

does not move (approximately 5 minutes after turning off the vacuum pump).

¤ŒDisconnect the charge hose from the vacuum pump.

- Vacuum pump oil. If the vacuum pump oil gets dirty or depleted, replenish as needed.

OPEN

Vacuum pump

Gas side

Liquid side

Indoor unit

Outdoor unit

Open

3-Way valve

Open

3-Way valve

–36–

Page 35

7.4 Gas Charging

1) Cooling mode (After Evacuation)

• Procedure

¤ Connect the charge hose to the charging cylinder.

• Connect the charge hose which you disconnected from the vacuum pump to the valve at the bottom of the cylinder.

• If you are using a gas cylinder, use a scale and reverse the cylinder so that the system can be charged with liquid.

¤ŁPurge the air from the charge hose.

• Open the valve at the bottom of the cylinder and press the check valve on the charge set to purge the air. (Be careful of the liquid refrigerant). The procedure is the same if using a gas cylinder.

¤ØOpen the valve (Lo side) on the charge set and

charge the system with liquid refrigerant.

• If the system can not be charged with the specified amount of refrigerant, it can be charged with a little at a time (approximately 150g each time) while operating the air conditioner in the cooling cycle; however, one time is not sufficient, wait approximately 1 minute and then repeat the procedure (pumping down-pin).

¤ŒImmediately disconnect the charge hose from the

3-way(gas side) valve's service port.

• Stopping partway will allow the gas to be discharged.

• If the system has been charged with liquid refrigerant while operating the air conditioner turn off the air conditioner before disconnecting the hose.

¤º Mount the valve stem nuts and the service port

nut.

•

Use a torque wrench to tighten the service port nut.

• Be sure to check gas leakage.

This is different from previous procedures. Because you are charging with liquid refrigerant from the gas side, absolutely do not attempt to charge with larger amounts of liquid refrigerant while operating the air conditioner.

–37–

Charging cylinder

Indoor unit

Check valve

OPEN

(1)

Liquid side

Gas side

3-Way valve

Open

Outdoor unit

Page 36

–38–

2) Heating Mode

(After Evacuation)

OPEN

(1)

Gas side

Liquid side

Indoor unit

Check valve

Charging cylinder

Outdoor unit

Open

3-Way valve

• Procedure

¤ Connect the charge hose to the charge cylinder.

• Connect the charge hose which you disconnected from the vacuum pump to the valve at the bottom of the cylinder.

• If you are using a gas cylinder, use a scale and reverse the cylinder so that the system can be charged with liquid.

¤ŁPurge the air from the charge hose.

¤Ø Open the valve (Lo side) on the charge set and

charge the system with liquid refrigerant.

¤ŒImmediately disconnect the charge hose from the

3-way valve's service port.

• Stopping partway will allow the gas to be discharged.

• If the system has been charged with liquid refrigerant while operating the air conditioner turn off the air conditioner before disconnecting the hose.

¤º

Mount the valve stem nuts and the service port nut.

Use a torque wrench to tighten the service port nut.

- Be sure to check gas leakage.

Page 37

8. Troubleshooting Guide

–39–

In general, possible trouble is classified as two causes. The one is so called 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 runs but ineffective cooling

Ineffective Cooling or Heating

Check outdoor coil (heat exchanger) & 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 ; COOLING : 7~10°C HEATING : 15~17°C

Check heat load rise at cooling operation.

Unexpected residue

Added electrical utensil

Check inside gas pressure.

Adjust refrigerant charge.

Malfunction of compressor.

Replacement of compressor

Check of cold (warm) air circulation for smooth flow.

Dirty indoor coil (heat exchanger.)

Malfunction of fan.

Clogging of air filter.

Obstruction at air outlet.

Stop of auto air-swing.

Countermeasure against above trouble.

Check clogging in refrigeration circuit.

Repair clogging in refrigeration circuit.

Page 38

–40–

Failures to Start

Check of circuit breaker and fuse.

Check control switch.

Fan only fails to start

Improper wiring

Defect of fan motor capacitor.

Irregular motor resistance

( Ω )

Irregular motor insulation

( Ω )

Replacement of fan motor.

Improper electric heater

Replacement of electric heater

Regular but fails to start.

Replacement of compressor

Electric heater is not energized

Loose terminal connection.

Improper wiring

Irregular motor resistance ( Ω

)

Irregular motor insulation ( Ω

)

Replacement of compressor

Drop of power voltage

Capacitor check

Replacement

Compressor only fails to start

Defect of compressor capacitor

Check power source.

Check control switch setting.

Page 39

–41–

PACKAGE AIR CONDITIONER VOLTAGE LIMITS

8.1 No cooling and heating operation performed

1) Both the blower and the compressor do not work

NAME PLATE RATING MINIMUM MAXIMUM

380 - 415 V 342 V 456 V

2) Only blowers do not work

WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY

Other parts than the unit

Magnetic switch for compressor & fan motor

Operating switch

Protection devices

Electric supply interrupted Defective power wiring Cut of power fuse

Too low voltage

Control point is on condition of "OFF" due to trouble.

Troubled or defective contactor

Opened the contact point with trouble

Measure it with a tester in case that the same power source is supplied to other equipment than the unit, what and where trouble can be discovered by checking the operation of other equipment.

Measure it with a tester.

Make short-circuit, then measure it with a tester.

Check it with the eyes or tester.

Repair a switch box and is relative instrument.

Replacement of fuse Request a power

supplier to repair.

Check the power source. Use a thick cable if necessary.

Replace it if necessary.

Repair or replace it.

Discover the trouble cause and push the rest button.

WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY

Air volume change over switch

Capacitor

Troubled or defective contact point

Defected

Check it with the eyes or a tester

Check it with a tester.

Repair or replace it.

Replace it.

Page 40

–42–

3) Only outdoor fan does not work

WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY

Motor

Electric Wiring

Over-heated Layer short

Open wire on operation Short circuited on

operation

Check how it is insulated.

Check it with a tester.

Repair or replace it.

Rewiring or repair.

4) Only compressor does not work

WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY

Magnetic switch for compressor motor

Compressor motor

Compressor

High pressure switch

Electric circuit

Defective contact, magnetic coil troubled.

Troubled over-heated (layer short)

Troubled or over-heated (lock)

Troubled or defective contact or operating

Defective connection or disconnection of the circuit for compressor.

Check it with the eyes on with a tester.

Check how it is insulated.

Groaned noise of motor

Check it with a tester.

Repair or replace it.

Replace or repair the compressor.

Repair or replace it.

Replace it if necessary.

Rewiring or push reset button.

Page 41

–43–

Note: Use an appropriate measuring instrument for readjustment.

*1: Check the High-pressure switch indication. *2: Check the Low- pressure switch indication.

8.2 The Units discontinue after the operation started

WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY

Other parts than the unit

Outdoor coil

In-condensable gas blended.

High pressure switch

Refrigerant

Outdoor Fan

Improper opening of the service valves in the refrigerant line

Coil is dirty *1

Air intruded into the refrigerant pipe line *1

Improper adjustment

A shortage of refrigerant amount. * 2

Reverse rotation of fan Obstacle Air short circuit *1

Checking

In the event that difference between the saturating temperature corresponding to high pressure and the temperature of air discharged from the outdoor coil is more than 15°C, incondensable gas may be blended.

Check it with a pressure gauge.

Confirm the wind blowing out.

Check it with eyes.

Open it properly

Wash it by means of something like chemical washing.

Extract air by vacuum pump, then recharge the refrigerant.

Readjust it to normal operating pressure. (Note) Don't alternate the specified adjusting pressure. If the adjusted pressure exceeds the specified range, it will cause a great accident.

Recharge the refrigerant. Repair the spot where it leaks.

If reversed, connect interchanged wires to each terminal. Power wirings.

Page 42

–44–

8.3 The unit is working, but not cooling and heating sufficiently (Both blower and compressor are working)

WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY

Load

Air flow

Short air volume

Refrigerant

Air passage

Air filter

Much heat load

Obstacle disturbs Intake of uniform wind.

Reverse rotation of blower.

Shortage in the charged refrigerant.

Improper or foreign bodies

Clogged with dust

Heat load increased. Window or door has many cracks or gaps.

Checking

Coil inlet pipe is frosted

Checking

Do necessary disposal respectively.

Correct it.

Replenish it. (Repair the leakage spot).

Correct or clear the foreign bodies.

Cleaning

8.4 All the functions are performed normally, but very noisily and

much vibratively.

WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY

Compressor

Blower

Screws

• Checking

Checking

• Remove the shipping bracket.

• Replace the

compressor

• Repair or replace it.

• Clear the other material

Repair

Liquid refrigerant flooding back from the evaporator.

Compressor shipping bracket is not removed.

Faulty discharge valve and suction valve.

Fan broken. Other materials intruded.

Looseness or fail-off of screws

• Check for refrigerant over-charge.

• Check to see if the intaking air temperature is extremely cold.

• Check for insufficient air flow quantity.

Page 43

–45–

WHAT TROUBLED COMPLAINTS HOW TO CHECK REMEDY

Electric troubles (Magnetic contactor)

Others

Defective contact. Defective contact point. Rusting and faults in the iron core contact face. Defective contact of the operating switch.

Improper installation

Checking

Repair and clean or replace it.

Correct it.

Fault Cause Check/Correcitve Action

High Discharge

Low Discharge

High Suction Pressure

Low Suction Pressure

Condenser cooling air extremely hot or insufficient air flow through the condenser

Inside of the condenser tube is clogged.

Air in the refrigeration cooling cycle.

Suction pressure is higher than standard.

Faulty discharge valves or suction valves of the compressor.

Refrigerant low-charge or leakage.

Suction pressure is lower than standard. Intake air extemely hot or excessive air flow

through the evaporator coil.

Refrigerant over-charge. Faulty discharge valve or suction valve of

the compressor. Discharge pressure is higher than standard

Intake air extremely cold or insufficient air flow through the evaporator coil.

Refrigerant short-charge or leakage.

Restricted liquid in the suction line.

1. Check the operation of the outdoor motor .

2. Check discharge and suction, air circulation.

Clean condenser coil.

Purge air from the cycle.

See "High Suction Pressure".

1. Check unit operation input

2. Check the suction pressure.

Add refrigerant: repair leakage if any.

See "Low Suction Pressure".

1. Check fresh air, intake or check for

leakage of the return air.

2. Check air flow quantity.

Purge the refrigerant. Check the operating input.

See "High discharge Pressure".

1. Check air flow quantity.

2. Check air filter .

3. Check evaporator coil frosting

Add refrigerant, repair leakage, if any.

Check the capillary tube and the strainer.

8.5 Trouble checking by protection devices

Page 44

–46–

Fault Cause Check/Correcitve Action

Internal Thermostat Cut-Off

Overcurrent Relay for Compressor Cut-Off

Overcurrent Relay for Fan Motor Cut-Off

Fuse Blown

Disconnection and Faulty Contact

Discharge pressure is lower than standard.

Single or three phases running.

High or low voltage or phase unbalance.

Refrigerant short charge or leakage.

Compressor frequently stops and starts.

Discharge and suction pressure are extremely high.

High or low voltage, or phase unbalance. Single or three phases running

Faulty compressor motor.

Loose connections. Compressor frequently stops and starts.

High or low voltage, or phase unbalance. Single or three phases running.

Faulty fan motor.

Loose connection. Faulty fan bearing. Loose connections. Single or three phase running.

Faulty motor.

Disconnection.

Faulty contact.

See "Low Discharge Pressure".

Check the power supply line and the contactor.

Check the voltage and phase unbalance.

Add refrigerant, repair leakage, if any.

Check thermistor operation, or any other cause for frequent stop and start operation.

See "High Discharge Pressure" or "High Suction Pressure".

Check the voltage and phase unbalance. Check the power supply line and the

contact. Check electric resistance among the

compressor terminals, and from the terminals to ground.

Check the electric connections. Check the operation of the thermistor, or

any other cause for frequent stop.

Check the voltage and electric wiring. Check the power supply line and the

contactor. Check the fan motor and wiring. Check the elelctric connections.

Check repair or replace the bearing. Check the electric connections.

Check the power supply line. Check electric resistance among motor

housing, and from the terminals to ground.

1. Check the wires and connect where necessary.

2. Check the contact holding coil.

Check the contact in the magnetic contact, the over-current relay, the pressure control switch, the operation switch, the auxiliary relay.

Page 45

–47–

8.6 Electronic Parts Troubleshooting Guide

1) No cooling operation performed.

YES

Is the AC220V

(AC 240 V) between Connector(CN-

outunit) ¥Land ¥Nof Main

P.C.B

ON/OFF S/W ON

Is the unit operating?

Is the input power

AC220V (AC240V) at COMP

Magnetic coil?

Check the magnetic contactor of outdoor unit.

Is it Cooling mode?

Room temp, > Set temp?

Is the DC5V at 14

pin of IC1(MICOM)

Replacement ICO2M, RY-Comp

Replacement (MICOM)

Room temp, >set temp setting

Select the cooling operation mode.

Check the wiring diagram.

Page 46

–48–

2) Indoor fan does not operate.

YES

YES YES YES

YES

NONONO

NO NO NO

Is the unit

operating?

Is the DC5V at 20 pin

of MICOM?

Is the DC12V at each

terminal of RY1 coil of

SUB PCB ASM?

Replacement IC03M

Is the AC220V (240V)

between "C" and "H" of

SUB P.C.B?

Replacement RY1 of

SUB PCB

Check the motor winding

Replacement RY2 of

SUB PCB

Replacement RY3 of

SUB PCB

Is the AC220V (240V)

between "C" and "M" of

SUB P .C.B?

Is the AC220V (240V)

between "C" and "L" of

SUB P.C.B?

Is the DC12V at each

terminal of RY2 of SUB

PCB ASM?

Is the DC12V at each

terminal of RY3 of SUB

PCB ASM?

Is the DC5V at 21 pin

of MICOM?

Is the DC5V at 22 pin

of MICOM?

Replacement

MICOM and check

the EVA-Th

ON/OFF S/W ON

Page 47

–49–

3) The unit does not operate.

YES

4) Timer control does not operate.

Replacement

MICOM

Is the AC220V

(240V) at Trans input terminal?

Is the AC12-18V at

Trans (2nd)?

Is the connector of

Main/Display correct?

Is the DC5V between PIN64

and PIN 32 of MICOM?

Replacement Main PCB ASM

1. Replacement IC03D

2. Replacement Main PCB ASM

Check the connector of Main/Display

Replacement Trans

1. Check the electric connections

2. Check the fuse of Main PCB ASM

Page 48

–50–

4) No heating operation performed.

YES

ON/OFF S/W ON

Is the AC220V

(AC 240 V) between connector

(CN-outunit) ¥Land ¥Nof Main

P.C.B

Is the input power AC220V

(AC240V) at COMP magnetic coil

contactor?

Is it heating mode?

Room temp <Set temp?

Is the DC5V

at 14 pin of MICOM

Is the DC5V at 18 pin of

MICOM

Is the DC12V

at each terminal?

(RY-4way COIL)

Is the

AC220V (AC 240 V) between

connector(4WAY) and CN-outunit ¥L of

Main P.C.B

Is the DC12V at

each terminal? (RY -Comp)

Replacement RY -4way

Replacement IC02M

Replacement RY3

Is the AC220V

(AC 240 V) between connector(CN-outunit)

¥Land ¥N of Main

P.C.B

Check the wiring diagram.

Replacement MICOM

Replacement IC02M

Room temp. < Set temp. Setting

Replacement MICOM

Select the heating operation mode.

Check the COMP magnetic contactor of outdoor unit.

Check the wiring

connection

Is the unit operating?

Page 49

–51–

5) No heater operation performed.

YES

Is the heating operating?

Is the Heat S/W of Main

PCB "ON"?

Heat S/W "ON"

Heater S/W "ON"

Replacement MICOM

Replacement IC02M

Replacement RY -Heater

Is the heater S/W of Main

PCB"ON"?

Is the DC 5V at 58 pin of

MICOM

Is the DC 12V at eack terminal?

(RY-Heater)

Is the

AC220V (AC 240 V) between

connector(HEA TER) and CN-outunit ¥Lof

Main P.C.B

Check the heater wiring

Select the heating operation mode.

Page 50

9. Electronic Control Device

–52–

9.1 Main P.C.B ASSY

Page 51

–53–

9.2 DISPLAY P.C.B ASSY

9.3 SUB P.C.B ASSY

PWB: 6870AQ2241 ASM: 6871AQ2242

CN-INPUT

CN-RELAY

CN-MOTOR

FUSE

250V/T10A

RY1 (HIGH)

RY2 (MIDDLE)

RY3 (LOW)

9.4 DE-ICER P.C.B ASSY

Page 52

10. Schematic Diagram

–54–

Circuit and Troubleshooting

Page 53

11. Exploped View and Replacement Parts List

–55–

45-3

45-2

43-2

43-1

45-3

45-1

25 29

31-1

27-1

Indoor Unit

Exploded View

Page 54

–56–

Page 55

–57–

1 BASE PAN 3040AP2624P 3040AP2624P 3040AP2624P 1 2 PANEL ASSY SIDE 3721AP3446A 3721AP3446A 3721AP3446A 1 3 PANEL ASSY SIDE 3721AP3446B 3721AP3446B 3721AP3446C 1 4 PANEL ASSY SIDE 3721AP3465E 3721AP3465A 3721AP3465C 1 5 PANEL ASSY SIDE 3721AP3465F 3721AP3465B 3721AP3465D 1 6 PANEL ASSY REAR-L 3720AP2221A 3720AP2221A 3720AP2221A 1 7 PANEL ASSY, SIDE 3721AP3466A 3721AP3466A 3721AP3466A 1 8 PANEL ASSY, SIDE 3721AP3466B 3721AP3466B 3721AP3466B 1

9 PANEL ASSY, REAR 3721AP3447A 3721AP3447A 3721AP3447C 1 10 COVER ASSY, TOP(INDOOR)" 3551AP2388A 3551AP2388B 3551AP2388B 1 11 DRAIN PAN ASS'Y 3087AP2281A 3087AP2281A 3087AP2281A 1 12 BRACKET 4810AP3333P 4810AP3333P 4810AP3333P 1 13 BRACKET 4810AP2296B 4810AP2296B 4810AP2296B 1 14 BRACKET 4810AP2298A 4810AP2298A 4810AP2298A 1 15 EVAPORATOR ASSY 5420AP2380A 5420AP2380A 5420AP2380A 1

15-1 EVAPORATOR ASSY, FINAL 5421AP2980A 5421AP2980B 5421AP2980B 1

16 TUBE ASSY 5211AP2678A 5211AP2678A 5211AP2678A 1 17 TUBE ASSY 5211AP3959B 5211AP3959B 5211AP3959B 1 18 TUBE CAPILLARY 5424AP3074G 5424AP3074G 5424AP3074G 15 19 EVA. BRACKET TOP 5420AP3302A 4811A30016A 4811A30016A 1 20 DOOR ASSY 3A02221A 3A02221A 3A02221A 1 21 MOTOR ASSY, AC 4681AP2411G 4681AP2411G 4681AP2411G 1 22 MOUNT ASSY, MOTOR 3G00788U 3G00788U 3G00788U 1 23 GRILLE ASSY INLET 5237AP2386A 5237AP2386A 5237AP2386A 1 24 GRILLE ASSY INLET 3530AP1109A 3530AP1109A 3530AP1109A 2 25 "FILTER ASSY, A/C" 5231AP3330A 5231AP3330A 5231AP3330A 1 26 BRACKET 5236AP3294A 5236AP3294A 5236AP3294A 1 27 GUIDE FILTER 4974AP2225A 4974AP2225A 4974AP2225A 1

27-1 GUIDE FILTER 4974AP2225B 4974AP2225B 4974AP2225B 1

28 BRACKET 4810AP3298A 4810AP3298A 4810AP3298A 2 29 BRACKET 4810AP4051A 4810AP4051A 4810AP4051A 1 30 BOARD CONTROL(INDOOR) 3500AP2293A 3500AP2293A 3500AP2293A 1 31 PWB(PCB)ASSY, MAIN 6871A20040U 6871A20040R 6871A20040R 1

31-1 PWB(PCB) ASSY, SUB 6871AQ2242A 6871AQ2242A 6871AQ2242A 1

32 CONTROL BOX(INDOOR) 4994AP2291A 4994AP2291A 4994AP2291A 1 33 HOUSING ASS'Y(MECH) 3661AP1139A 3661AP1139A 3661AP1139A 1 34 HOUSING ASS'Y(MECH) 3661AP1139B 3661AP1139B 3661AP1139B 1 35 FAN ASSY, BLOWER 2A00578R 2A00578R 2A00578R 2 36 CUT OFF 4A00085A 4A00085A 4A00085A 2 37 PANEL ASSY FRONT 3720AP1136P 3720AP1136P 3720AP1136P 1 38 HOLDER ASSY DISPLAY 4930AP1133C 4930AP1133C 4930AP1133C 1 39 DISPLAY ASSY(MECH) 3545A20004D 3545A20004M 3545A20004L 1 40 PWB(PCB) ASSY, DISPLAY 6871AQ3143Q 6871AQ3143R 6871AQ3143R 1 41 HOLDER, DISPLAY 3070AP2292K 3070AP2292K 3070AP2292K 1 42 WINDOW DISPLAY 3790AP3936Q 3790AP3936Q 3790AP7356C 1

No. DESCRIPTION Q’TY REMARK

PART No.

LP-F8081CL LP-F8081HL LP-F8081ZL

Page 56

–58–

43 KNOB 4940AP3422C 4940AP3422C 4940AP3422C 1

43-1 KNOB 4940AP3166E 4940AP3166E 4940AP3166E 1 43-2 KNOB 4940AP3326E 4940AP3326E 4940AP3326E 1

4940A30006A 4940A30006A 4940A30006A 1

44 KNOB

4940A30006B 4940A30006B 4940A30006B 1 4940A30006C 4940A30006C 4940A30006C 1 4940A30006D 4940A30006D 4940A30006D 1

45 GRILLE ASSY, DIFFUSER 3023AP2387B 3023AP2387B 3023AP2387B 1

45-1 GRILLE 4A01317Z 4A01317Z 4A01317Z 5 45-2 LOUVER, VERTICAL 3A00752Y 3A00752Y 3A00752Y 12 45-3 DECORATION 3508AP3328A 3508AP3328C 3508AP3328C 2

46 BARRIER ASSY 4791AP2300A 4791AP2300B 4791AP2300B 1 47 BARRIER INDOOR 4790AP3217A/B 4790AP3217A/B 4790AP3217A/B 1 48 CAPACITOR 2A00986S 2A00986S 2A00986S 1 49 CLAMP, CAPACITOR 4H00930D 4H00930D 4H00930D 1 50 ELECTRIC HEATER - - 5301A10001A 1

No. DESCRIPTION Q’TY REMARK

PART No.

LP-F8081CL LP-F8081HL LP-F8081ZL

Page 57

–59–

Outdoor Unit

Exploded View

4-1

4-2

4-4

4-3

12-8

Page 58

–60–

1 BASE ASSY 3041AP2606Q 1

2 COMPRESSOR 5417AP2982A 1

4-1 5403AP2618H 1 4-2

CONDENSER ASSY

5403AP2618H 1 4-3 5403AP2618H 1 4-4 5403AP2618H 1

5 LINK SHEET 4520AP4095A 2 6 BRACKET COND 4810A30028A 2 7 TUBE ASSY, (MANIFOLD IN) 5211A30050A 1 8 TUBE ASSY, (MANIFOLD IN) 5211A30050B 1

9 TUBE ASSY, (MANIFOLD OUT) 5211AP3868A 1 10 TUBE ASSY, (MANIFOLD OUT) 5211AP3868B 1 11 MESH(COVER FIN) 2A00191R 2 12 CONTROL BOX ASSY 4995AP2854D 1

12-1 CASE CONTROL 3110AP2592A 1 12-2 BOARD CONTROL 3500AP2591A 1 12-3 MAGNATIC CONTACTOR 2A01031C 1 12-4 PROTECTION RELAY 2A00999C 1 12-5 TERMINAL BLOCK 3A00493A 1 12-6 SH-CAPACITOR 2H00841J 2 12-8 TERMINAL BLOCK 4G00103A 1

13 REBBER MOUNTING 4022AP9183A 4 14 BRACKET 4H01811C 4 15 BUSHING 4830AP4182A 1 16 SUPPORT VALVE 4980AP2621A 1 17 VALVE SERVICE 2A00469C 1 18 VALVE SERVICE 2A00468B 1 19 COVER TUBING 3550AP2844P 1 20 SUPPORTER REAR 4980AP1265Q 1 21 SUPPORTER REAR 4980AP1265P 1 22 SUPPORTER FRONT 4980AP1264P 1 23 SUPPORTER FRONT 4980AP1263P 1 24 ORIFICE ASSY 4948AP1242P 1 25 MOUNT MOTOR ASSY 3A00434A 2 26 MOTOR 4680AP2610B 2 27 BUSHING BASE COMP 4A00077A 11 28 NUT 4H00947C 12 29 FAN ASSY 0A00026B 2 30 FAN LOCKER 4A01387A 2 31 SPRING LOCK WASHER 1WSD1000030 2 32 HEXAGON NUTS 1NHA1001206 2 33 GRILLE COVER 2A00144P 2

34-1 PANEL ASSY FRONT 3721AP2913P 1 34-2 PANEL ASSY FRONT 3721AP2913Q 1

35 COVER ASSY CONTROL 3551AP7047Z 1 36 PANEL INSTALL-U 3720AP3810P 1 37 BRACKET INSTALL-L 3720AP3814P 1 39 BRACKET F.P 4810AP7078A 1 40 COVER FAN 3550AP3912A 1 41 HUB FAN 3250AP3964A 2 43 HIGH PRESSURE SWITCH 6600AG3057A 1 44 TUBE ASSY,DISCHARGE 5211A30104A 1 45 TUBE ASSY,CONDENSER 5211A30105A 1

No. DESCRIPTION Q’TY REMARK

PART No.

LP-F8081CL

Page 59

–61–

Outdoor Unit

Exploded View

4-6

4-4

4-7

4-9

4-8

4-3

20-2

4-2

4-5

4-1

21-1

131118

Page 60

–62–

1 BASE ASSY 3041AP2606V 1

2 COMPRESSOR 5417AP2982A 1

3 ACCUMULATOR 3A02139U 1

4 CONTROL BOX ASSY 4995A20002B 1

4-1 CASE CONTROL 3110AP2592A 1 4-2 BOARD CONTROL 3500AP2591A 1 4-3 TERMINAL BLOCK 3A00493A 1 4-4 TERMINAL BLOCK 4G00103A 1 4-5 MAGNATIC CONTACTOR 2A01031C 1 4-6 SH-CAPACITOR 2H00841J 2 4-7 RELAY 3A00261C 1 4-8 TERMINAL BLOCK 3H00390A 1 4-9 DEICER PCB ASSY 6871A20015T 1

4-10 3 PHASE DETECTOR 6871A30015D 1

5 CONDENSER ASSY 5403A20030E 1

6 CONDENSER ASSY 5403A20030F 1

7 CONDENSER ASSY 5403A20030G 1

8 CONDENSER ASSY 5403A20030H 1

9 LINK SHEET 4520AP4095A 2 10 BRACKET COND 4810AP3697A 2 11 TUBE ASSY, (MANIFOLD IN) 5211A30269A 1 12 TUBE ASSY, (MANIFOLD IN) 5211A30269B 1 13 TUBE ASSY, (MANIFOLD OUT) 5211A30270C 1 14 TUBE ASSY, (MANIFOLD OUT) 5211A30270D 1 15 TUBE ASSY REVER SING 5211A20078B 1 16 COIL ASYS REVERSING 3A02028B 1 17 TUBE ASSY CHECK VALVE 5211A30271A 1 18 TUBE ASSY CHECK VALVE 5211A30271B 1 19 TUBE ASSY CAPILLIARY 5211A20129B 2 20 CORE VALVE 3A01902A 1

21-1 HIGH PRESSURE SWITCH 6600AG3057A 1 21-2 HIGH PRESSURE SWITCH 3A01100A 1

22 MESH 2A00191Q 1 25 SUPPORT VALVE 4980AP2621A 1 26 BRACKET FRONT 4810AP7078A 1 27 VALVE SERVICE 2A00469H 1 28 VALVE SERVICE 2A00468E 1 29 COVER TUBING 3550A20003P 1 30 SUPPORTER REAR 4980AP1265Q 1 31 SUPPORTER REAR 4980AP1265P 1 32 SUPPORTER FRONT 4980AP1264P 1 33 SUPPORTER FRONT 4980AP1263P 1 34 ORIFICE ASSY 4948AP1242P 1 35 MOUNT MOTOR ASSY 3A00434A 2 36 MOTOR 4680AP2610B 2 37 BUSHING BASE COMP 4A00077A 8 38 NUT 4H00947C 8 39 FAN ASSY 0A00026B 2

No. DESCRIPTION Q’TY REMARK

PART No.

LP-F8081HL/ZL

Page 61

–63–

40 FAN LOCKER 4A01387A 2 41 SPRING LOCK WASHER 1WSD1000030 2 42 HEXAGON NUTS 1NHA1001206 2 43 GRILLE COVER 2A00144P 2 44 PANEL ASSY FRONT 3721AP2913P 1 45 PANEL ASSY FRONT 3721AP2913Q 1 46 COVER ASSY CONTROL 3551AP7047Z 1 47 PANEL INSTALL-U 3720AP3810P 1 48 BRACKET INSTALL-L 3720AP3814P 1 49 COVER FAN 3550AP3912A 1 51 TUBE ASSY,CONDENSER 5211A30219A 1 52 TUBE ASSY,CONNECTOR 5211A30272A 1

No. DESCRIPTION Q’TY REMARK

PART No.

LP-F8081HL/ZL

Page 62

P/No.: 3828A30074P

February, 2000

Printed in Korea

LG LP-F8081CL, LP-F8081HL, LP-F8081ZL Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual