LG LS-C1823RM1, LS-C1863R, LS-C1863W, LS-C1863B, LS-C1863D Service Manual
...
LG
Room
Air Conditioner
SERVICE MANUAL
LG
CAUTION
website http://www.lgservice.com
• BEFORE SERVICING THE UNIT, READ THE SAFETY
PRECAUTIONS IN THIS MANUAL.
• ONLY FOR AUTHORIZED SERVICE PERSONNEL.
MODELS: LS-C1863R/W/B/D/M/CM0
LS-H1863R/W/B/D/M/CM0
LS-C2463R/W/B/D/M/CM0
LS-H2463R/W/B/D/M/CM0
LS-C1823R/W/B/D/M/CM0
LS-C1823R/W/B/D/M/CM2
LS-H1823R/W/B/D/M/CM0
LS-C2423R/W/B/D/M/CM0
LS-H2423R/W/B/D/M/CM0
AS-H2463R/D/M/WM1
AS-H1863B/M/R/WM0
AS-H2463R/D/M/WM1
LS-C2463B/C/D/M/RM1
LS-C1823RM1
LS-H1863B/D/M/R/WM1
AS-H1863*M3
AS-H2463*M3
LS-H1863*M3
LS-C2463*M3
LS-H2463*M3
LS-C1863*M3
LS-C2463*M4
2 Room Air Conditioner
Air Conditioner Service Manual
TABLE OF CONTENTS
LG Model Name...............................................................................................................................................3
Safety Precautions..........................................................................................................................................4
Dimensions......................................................................................................................................................8
Symbols used in this Manual......................................................................................................................8
Indoor Unit.................................................................................................................................................8
Outdoor Unit...............................................................................................................................................9
Installation.....................................................................................................................................................12
Select the best Location ..........................................................................................................................12
Piping Length and Elevation.....................................................................................................................13
Fixing Installation Plate ............................................................................................................................14
Drill a Hole in the Wall..............................................................................................................................14
Flaring Work.............................................................................................................................................15
Connecting the Piping ..............................................................................................................................16
Connecting the Cables to the Indoor Unit ................................................................................................22
Connecting the Cables to the Outdoor Unit..............................................................................................23
Checking the Drainage.............................................................................................................................23
Forming the Piping ...................................................................................................................................24
Air Purging ...............................................................................................................................................25
Air Purging with Vacuum Pump................................................................................................................25
Test Running ............................................................................................................................................27
Operation.......................................................................................................................................................28
Function of Controls .................................................................................................................................28
Display Function ......................................................................................................................................35
Self-diagnosis Function............................................................................................................................36
Remote Control Operations......................................................................................................................37
Disassembly..................................................................................................................................................38
Indoor Unit................................................................................................................................................38
Troubleshooting Guide.................................................................................................................................41
Refrigeration Cycle Diagram ....................................................................................................................41
2-way, 3-way Valve .................................................................................................................................42
Cycle Parts...............................................................................................................................................47
Electronic Parts ........................................................................................................................................48
Schematic Diagram.......................................................................................................................................55
Electric Control Device.............................................................................................................................55
Wiring Diagram.........................................................................................................................................56
Components Location ..............................................................................................................................58
Product Specifications.................................................................................................................................60
Exploded View...............................................................................................................................................62
Replacement Parts List ................................................................................................................................65
Service Manual 3
LG Model Name
LG Model Name
12 - 345678910
Code Type Code of Model Meaning
1 Producing Center, A~Z L: Chang-won R22 N: India
Refrigerant
A: Chang-won R410A Z: Brazil
C: Chang-won R407C D: Indonesia
T: China X: Mexico
K: Turkey R22
V: Vietnam
U: China R410A
E: Turkey R410A
S: Out Sourcing
H: Thailand
2 Product Type A~Z S: Split Type Air Conditioner
3 Cooling/Heating/Inverter A~Z C: Cooling only
H: Heat pump
X: C/O + E/Heater
Z: H/P + E/Heater
V: AC Inverter C/O
N: AC Inverter H/P
Q: DC Inverter C/O
W: DC Inverter H/P
4, 5 Capacity 0~9 Cooling/Heating Capacity
Ex. "09" → 9,000 Btu/h
6 Electric Range 1~9 1: 115V/60Hz, A: 220V, 50Hz, 3Phase
A~Z 2: 220V/60Hz B: 208~230V, 60Hz, 3Phase
3: 208-230V/60Hz C: 575V, 50Hz, 3Phase
5: 200-220V/50Hz D: 440~460, 60Hz, 3Phase
6: 220-240V/50Hz E: 265V, 60Hz
7: 110V, 50/60Hz F: 200V, 50/60Hz
8: 380-415V/50Hz
9: 380-415V/60Hz
7 Chassis 1~9 Name of Chassis of Unit
Ex. 3 → S3 Chassis
8 Look A~Z Look,
Color (Artcool Model)
9 Function A~Z
10 Serial No. 1~9 LG Model De
* ARTCOOL COLOR
velopment Serial No.
Basic A
Basic+4Way B
Plasma Filter C
Plasma Filter+4 Way D
Tele+LCD E
Tele+LCD+Nano plasma+4Way F
Nano Plasma F+(A/changeover)+A/clean+Low A G
Nano Plasma F+(A/changeover)+A/clean+4way+Low A H
Tele+LED+4way I
Internet J
Plasma F+4Way+Oxy generator K
Nano Plasma F+(A/changeover)+A/clean L
Nano Plasma F+(A/changeover)+A/clean+4way M
Nano Plasma F+(A/changeover)+A/clean+PTC N
Nano Plasma F+(A/changeover)+Autoclean+4way+PTC P
Nano Plasma F+(A/changeover)+A/clean+4way+Low A+PTC Q
Negative ION+A/Clean R
(Nano)Plasma+Negative ION+A/Clean S
4way+(Nano)Plasma F+Negative ION+Healthy dehumidification+A/Clean
T
Nano Plasma F+4Way+(A/changeover)+A/clean+Oxy generator U
4way+(Nano)Plasma F+Negative ION+Healthy dehumidification+A/Clean+Oxy generator
V
Dry Contact W
Wired Remocon 8
R Mirror
W White Wood
B Blue
D Wood
M Metal
C Cherry
N Walnut
A Gogh
S Sisley
Q Quran
K Mecca
2004
8 Room Air Conditioner
Dimensions
Dimensions
Installation plate
D
H
W
W mm 1170
H mm 315
D mm 173
Model
Dimension
INDOOR UNIT
Indoor Unit
This symbol alerts you to the risk of electric shock.
This symbol alerts you to hazards that may cause harm to the
air conditioner.
This symbol indicates special notes.
NOTICE
Symbols used in this Manual
W mm 870 870
H mm 655 800
D mm 320 320
L1 mm 370 370
L2 mm 340 340
L3 mm 25 25
L4 mm 630 775
L5 mm 25 25
L6 mm 546 546
L7 mm 162 162
L8 mm 162 162
L9 mm 54 54
L10 mm 74.5 74.5
L11 mm 79 79
LS-C1863R/W/B/D/M/CM0, LS-H1863R/W/B/D/M/CM0
LS-C2463R/W/B/D/M/CM0, LS-H2463R/W/B/D/M/CM0
LS-H2423R/W/B/D/M/CM0, AS-H1863B/M/R/WM0
AS-H2463B/M/R/WM0, LS-C2463B/C/D/M/RM1
LS-C1823RM1, LS-H1863B/D/M/R/WM1
LS-H1863*M3, LS-C2463*M3, LS-H2463*M3
LS-C1863*M3, LS-C2463*M4
AS-H2463R/D/M/WM1
Service Manual 9
Outdoor Unit
Dimensions
W
L7 L6 L8 L9
D
L1
L2
L3
L10L11
L4L5
H
Gas side
Liquid side
MODEL
DIM
10 Room Air Conditioner
Dimensions
W
L2
L3
L1
D
H
L4
L5
Gas side
(3-way valve)
Liquid side
(2-way valve)
MODEL
DIM unit
W mm 840
H mm 577
D mm 276
L1 mm 287
L2 mm 64
L3 mm 518
L4 mm 10
L5 mm 100
LS-C1823R/W/B/D/M/CM2, AS-H1863*M3
LS-C2423R/W/B/D/M/CM0, AS-H2463*M3
Service Manual 11
Dimensions
W
D
L1
L2
H
L3
L4
L5L6 L7 L8
L9
L10
Liquid side
2-way valve
Gas side
3-way valve
MODEL
DIM unit
W mm 801
H mm 555
D mm 262
L1 mm 339
L2 mm 37
L3 mm 543.6
L4 mm 11.4
L5 mm 591
L6 mm 105
L7 mm 105
L8 mm 72.5
L9 mm 86.4
L10 mm 77
LS-C1823R/W/B/D/M/CM0
LS-H1823R/W/B/D/M/CM0
12 Room Air Conditioner
Installation
Installation
Indoor unit
1. Do not have any heat or steam near the unit.
2. Select a place where there are no obstacles in front
of the unit.
3. Make sure that condensation drainage can be conveniently routed away.
4. Do not install near a doorway.
5. Ensure that the interval between a wall and the left
(or right) of the unit is more than 50cm. The unit
should be installed as high as possible on the wall,
allowing a minimum of 10cm from ceiling.
6. Use a stud finder to locate studs to prevent unnecessary damage to the wall.
Outdoor unit
1. If an awning is built over the unit to prevent direct
sunlight or rain exposure, make sure that heat radiation from the condenser is not restricted.
2. Ensure that the space around the back and sides is
more than 10cm. The front of the unit should have
more than 70cm of space.
3. Do not place animals and plants in the path of the
warm air.
4. Take the weight of the air conditioner into account
and select a place where noise and vibration are minimum.
5. Select a place where the warm air and noise from the
air conditioner do not disturb neighbors.
Select the best Location
More than 10cm
More than
5cm
More than 2.3m
More than
5cm
CAUTION: Install the indoor unit on the wall where the height from the
floor is more than 2 meters.
More than 10cm More than 10cm
More
than 60cm
More than 60cm
More than 70cm
Service Manual 13
Installation
Piping Length and Elevation
Outdoor unit
Indoor unit
A
B
Outdoor unit
Indoor unit
A
B
A
Oil trap
Outdoor unit
Indoor unit
B
If piping length is more than 5m
CAUTION: Capacity is based on standard length and maximum allowance length is
on the basis of reliability.
Oil trap should be installed every 5~7 meters.
Pipe Size
Capacity
(Btu/h)
GAS LIQUID
Max.
Length
A
(m)
Additional
Refrigerant
(g/m)
Max.
Elevation
B
(m)
Standard
Length
(m)
5k~14k
3/8"(Ø9.52) 1/4"(Ø6.35) 4 or 7.5 20
1/2"(Ø12.7) 1/4"(Ø6.35) 4 or 7.5
20
20
1/2"(Ø12.7) 1/4"(Ø6.35) 4 or 7.5
18k~28k 5/8"(Ø15.88) 1/4"(Ø6.35) 4 or 7.5
5/8"(Ø15.88) 3/8"(Ø9.52) 4 or 7.5
30k~38k
5/8"(Ø15.88) 3/8"(Ø9.52) 7.5
3/4"(Ø19.05) 3/8"(Ø9.52) 7.5
50
30
30
20
15
30
15
30
30
30
30
7
15
7
15
15
15
15
14 Room Air Conditioner
Installation
The wall you select should be strong and solid
enough to prevent vibration
1. Mount the installation plate on the wall with
type "A" screws. If mounting the unit on a concrete wall, use anchor bolts.
• Mount the installation plate horizontally by aligning
the centerline using a level.
2. Measure the wall and mark the centerline. It is
also important to use caution concerning the
location of the installation plate-routing of the
wiring to power outlets is through the walls typically. Drilling the hole through the wall for piping
connections must be done safely.
Fixing Installation Plate
Installation Plate
Type "A" screw
Installation plate
Ø70mm
Left rear piping Right rear piping
C
D
B
A
Ø70mm
Left rear piping Right rear piping
B
A
D
C
Right rear piping
B
A
D
C
Installation plate
(SU)
(SZ)
(S3)
Installation plate
• Drill the piping hole with a ø70mm hole core drill.
Drill the piping hole at either the right or the left
with the hole slightly slanted to the outdoor side.
Drill a Hole in the Wall
5-7mm
(3/16"~5/16")
Indoor
WALL
Outdoor
ABCD
SZ
35 33 156 33
(7k~9k)
SU
92 44 67 44
(11k~14k)
S3
58 3 292 3
(18k~26k)
CHASSIS
(Grade)
Distance (mm)
• For S3 chassis, the center of the unit is different
from that of the Installation plate.
Service Manual 15
Installation
Flaring Work
Main cause for gas leakage is due to defect in flaring work. Carry out correct flaring work in the following procedure.
Cut the pipes and the cable.
1. Use the piping kit accessory or the pipes purchased
locally.
2. Measure the distance between the indoor and the
outdoor unit.
3. Cut the pipes a little longer than measured distance.
4. Cut the cable 1.5m longer than the pipe length.
Burrs removal
1. Completely remove all burrs from the cut cross section of pipe/tube.
2. Put the end of the copper tube/pipe in a downward
direction as you remove burrs in order to avoid dropping burrs into the tubing.
Putting nut on
• Remove flare nuts attached to indoor and outdoor unit,
then put them on pipe/tube having completed burr
removal.
(not possible to put them on after flaring work)
Flaring work
1. Firmly hold copper pipe in a die in the dimension
shown in the table below.
2. Carry out flaring work with the flaring tool.
Copper
pipe
90°
Slanted Uneven Rough
Pipe
Reamer
Point down
Flare nut
Copper tube
mm inch mm
Ø6.35 1/4 0~0.5
Ø9.52 3/8 0~0.5
Ø12.7 1/2 0~0.5
Ø15.88 5/8 0~1.0
Ø19.05 3/4 1.0~1.3
Outside diameter A
Bar
Copper pipe
Clamp handle
Red arrow mark
Cone
Yoke
Handle
Bar
"A"
16 Room Air Conditioner
Installation
Check
1. Compare the flared work with the figure by.
2. If a flared section is defective, cut it off and do flaring work again.
Indoor
1. Prepare the indoor unit's piping and drain hose for installation through the wall.
2. Remove the plastic tubing retainer(see the illustration by) and pull the tubing and drain hose away
from chassis.
3. Replace only the plastic tubing holder 1, not the
holder 2 in the original position.
1. Route the indoor tubing and the drain hose in the
direction of rear right.
2.
Insert the connecting cable into the indoor unit from
the outdoor unit through the piping hole.
• Do not connect the cable to the indoor unit.
• Make a small loop with the cable for easy connec-
tion later.
3. Tape the tubing, drain hose, and the connecting
cable. Be sure that the drain hose is located at the
lowest side of the bundle. Locating at the uper side
can cause drain pan to overflow inside the unit.
CAUTION: If the drain hose is routed inside
the room, insulate the hose with an insulation material* so that dripping from "sweating"(condensation) will not damage furniture
or floors.
*Foamed polyethylene or equivalent is recommended.
Inclined
Inside is shiny without scratches
Smooth all round
Even length
all round
Surface
damaged
Cracked Uneven
thickness
= Improper flaring =
Connecting the Piping
For right rear piping
Drain hose
Connecting
pipe
Connecting cable
Tape
Drain hose
Tubing holder 1
Tubing holder 2
Service Manual 17
Installation
4. Indoor unit installation
Hook the indoor unit onto the upper portion of the
installation plate.(Engage the two hooks of the rear
top of the indoor unit with the upper edge of the
installation plate.) Ensure that the hooks are properly seated on the installation plate by moving it left
and right.
Press the lower left and right sides of the unit
against the installation plate until the hooks engage
into their slots(clicking sound).
Connecting the piping to the indoor unit and drain
hose to drain pipe.
1. Align the center of the pipes and sufficiently tighten
the flare nut by hand.
2. Tighten the flare nut with a wrench.
3. When extending the drain hose at the indoor unit,
install the drain pipe.
Wrap the insulation material around the connecting portion.
1. Overlap the connection pipe insulation material and
the indoor unit pipe insulation material. Bind them
together with vinyl tape so that there may be no
gap.
2. Wrap the area which accommodates the rear piping
housing section with vinyl tape.
3. Bundle the piping and drain hose together by wrapping them with vinyl tape for enough to cover where
they fit into the rear piping housing section.
Drain hose
Connecting
cable
Indoor unit tubing Flare nut Pipes
Wrench
Indoor unit tubing
Open-end wrench (fixed)
Connection pipe
Flare nut
mm inch kg.m
Ø6.35 1/4 1.8
Ø9.52 3/8 4.2
Ø12.7 1/2 5.5
Ø15.88 5/8 6.6
Outside diameter Torque
Vinyl tape(narrow)
Adhesive
Drain pipe
Indoor unit drain hose
Plastic bands
Insulation material
Vinyl tape(narrow)
Connection pipe
Connecting cable
Vinyl tape (wide)
Wrap with vinyl tape
Indoor unit pipe
Pipe
Wrap with vinyl tape
Drain hose
Pipe
Vinyl tape(wide)
18 Room Air Conditioner
Installation
1. Route the indoor tubing and the drain hose to the
required piping hole position.
2. Insert the piping, drain hose, and the connecting
cable into the piping hole.
3.
Insert the connecting cable into the indoor unit.
• Don't connect the cable to the indoor unit.
• Make a small loop with the cable for easy connec-
tion later.
4. Tape the drain hose and the connecting cables.
5. Indoor unit installation
• Hang the indoor unit from the hooks at the top of
the installation plate.
• Insert the spacer etc. between the indoor unit and
the installation plate and separate the bottom of
the indoor unit from the wall.
Connecting the piping to the indoor unit and the
drain hose to drain pipe.
1. Align the center of the pipes and sufficiently tighten
the flare nut by hand.
2. Tighten the flare nut with a wrench.
3. When extending the drain hose at the indoor unit,
install the drain pipe.
For left rear piping
Drain pipe
Connecting
cable
1 2
Installation plate
Spacer
Indoor unit
8cm
Indoor unit tubing Flare nut Pipes
Wrench
Indoor unit tubing
Connection pipe
Flare nut
Open-end wrench (fixed)
Vinyl tape
Adhesive
Drain hose
Indoor unit drain hose
(narrow)
mm inch kg.m
Ø6.35 1/4 1.8
Ø9.52 3/8 4.2
Ø12.7 1/2 5.5
Ø15.88 5/8 6.6
Outside diameter Torque
Service Manual 19
Installation
Wrap the insulation material around the connecting portion.
1. Overlap the connection pipe heat insulation and the
indoor unit pipe heat insulation material. Bind them
together with vinyl tape so that there may be no
gap.
2. Wrap the area which accommodates the rear piping
housing section with vinyl tape.
3. Bundle the piping and drain hose together by wrapping them with cloth tape over the range within
which they fit into the rear piping housing section.
Reroute the pipings and the drain hose across the
back of the chassis.
Indoor unit installation
1. Remove the spacer.
2. Ensure that the hooks are properly seated on the
installation plate by moving it left and right.
3. Press the lower left and right sides of the unit
against the installation plate until the hooks engage
into their slots(clicking sound).
Plastic bands
Insulation material
Vinyl tape(narrow)
Connection
pipe
Connecting cable
Indoor
unit piping
Pipe
Vinyl tape
(wide)
Wrap with vinyl tape
Drain hose
Vinyl tape(narrow)
Pipe
Wrap with
vinyl tape(wide)
Piping for
passage through
piping hole
Drain hose
Connecting
cable
20 Room Air Conditioner
Installation
CAUTION: Installation Information
For left piping. Follow the instruction below.
Good case
• Press on the upper side of clamp and unfold the tubing to downward slowly.
Bad case
• Following bending type from right to left may cause damage to the tubing.
Service Manual 21
Installation
Outdoor
Align the center of the pipings and sufficiently tighten
the flare nut by hand.
Finally, tighten the flare nut with torque wrench until
the wrench clicks.
• When tightening the flare nut with torque wrench,
ensure the direction for tightening follows the arrow
on the wrench.
mm inch kg.m
Ø6.35 1/4 1.8
Ø9.52 3/8 4.2
Ø12.7 1/2 5.5
Ø15.88 5/8 6.6
Ø19.05 3/4 6.6
Outside diameter Torque
Outdoor unit
Liquid side piping
(Smaller diameter)
Gas side
piping
(Bigger
diameter)
Torque wrench
22 Room Air Conditioner
Installation
• Connect the cables to the indoor unit by connecting the wires to the terminals on the control board
dividually according to the outdoor unit connection. (Ensure that the color of the wires of the outdoor unit and the
terminal No. are the same as those of the indoor unit.)
• Before connecting the cables to the terminal block, remove the cables in the holder of the control cover and
do it.
Connecting the Cables to the Indoor Unit.
CAUTION:
• The above circuit diagram is subject to change without notice.
• The earth wire should be longer than the common wires.
• When installing, refer to the circuit diagram behind the panel front of the indoor unit.
• Connect the wires firmly so that they may not be pulled out easily.
• Connect the wires according to color codes, referring to the wiring diagram.
CAUTION: If a power plug is not
used, provide a circuit breaker
between power source and the unit
as shown by.
CAUTION:
The power cord connected to the "A" unit should be selected according to
the following specifications(Type "B" approved by HAR or SAA).
The power connecting cable connecting the indoor and outdoor unit should be selected
according to the following specifications (Type "B" approved by HAR or SAA).
Air
Conditioner
Main power source
Circuit Breaker
Use a circuit breake
or time delay fuse.
NORMAL
CROSS-SECTIONAL
AREA 0.75mm2
30k, 32k 36k, 38k
0.75 0.75
Cable Type(B) H07RN-F H07RN-F
NORMAL CROSS
-SECTIONAL AREA
Grade
(mm2)
(mm
2
)
(mm
2
)
5k~9k 12k~14K
0.75 1.0
Unit(A) Indoor Indoor
Cable Type(B) H05VV-F H05VV-F
NORMAL CROSS
-SECTIONAL AREA
Grade
7k~14k
1.0
Cable Type(B) H07RN-F
NORMAL CROSS
-SECTIONAL AREA
Grade
Service Manual 23
Installation
1. Remove the control cover from the unit by loosening the screw.
Connect the wires to the terminals on the control
board individually.
2. Secure the cable onto the control board with the
cord clamp.
3. Refix the control cover to the original position
with the screw.
4. Use a recognized circuit breaker "A"
between the power source and the unit.
A disconnecting device to adequately disconnect
all supply lines must be fitted.
Terminal block
Over 5mm
Cover control
Connecting cable
Connecting cable
CAUTION: After the confirmation of the above conditions, prepare the wiring as
follows:
1) Never fail to have an individual power circuit specifically for the air conditioner. As for the method of wiring,
be guided by the circuit diagram posted on the inside of control cover.
2) The screw which fasten the wiring in the casing 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 cause burn-out of the wires.)
3) Specification of power source.
4) Confirm that electrical capacity is sufficient.
5) See to that the starting voltage is maintained at more than 90 percent of the rated voltage marked on the
name plate.
6) Confirm that the cable thickness is as specified in the power source specification.
(Particularly note the relation between cable length and thickness. (Refer to page 24))
7) Always install an earth leakage circuit breaker in a wet or moist area.
8) The following would be caused by voltage drop.
• Vibration of a magnetic switch, which will damage the contact point, fuse breaking, disturbance of the normal func-
tion of the overload.
9) The means for disconnection from a power supply shall be incorporated in the fixed wiring and have an air
gap contact separation of at least 3mm in each active(phase) conductors.
Outdoor Unit
7ks~18k ~26k ~30k ~38k
15 20 30 40
Circuit
Breaker
(A)
Grade
Connecting the Cables to the Outdoor Unit
24 Room Air Conditioner
Installation
Checking the Drainage Forming the Piping
1. Checking the drainage.
• Pour a glass of water on the evaporator.
• Ensure the water flows through the drain hose of
the indoor unit without any leakage and goes out
the drain exit.
2. Drain piping
• The drain hose should point downward for easy
drain flow.
• Do not make drain piping like the following.
1. Form the piping by wrapping the connecting
portion of the indoor unit with insulation material and secure it with two kinds of vinyl tapes.
• If you want to connect an additional drain hose,
the end of the drain outlet should be routed above
the ground. Secure the drain hose appropriately.
2. In cases where the outdoor unit is installed
below the indoor unit perform the following.
• Tape the piping, drain hose and connecting cable
from down to up.
• Secure the tapped piping along the exterior wall
using saddle or equivalent.
3. In cases where the Outdoor unit is installed
above the Indoor unit perform the following.
• Tape the piping and connecting cable from down
to up.
• Secure the taped piping along the exterior wall.
Form a trap to prevent water entering the room.
• Fix the piping onto the wall by saddle or equiva-
lent.
Taping
Drain
hose
Pipings
Connecting
cable
Trap is required to prevent water
from entering into electrical parts.
Seal small openings
around pipings with a
gum type sealer.
Seal a small opening
around the pipings
with gum type sealer.
Trap
Trap
Downward slope
Do not raise
Accumulated
drain water
Tip of drain hose
dipped in water
Air
Waving
Water
leakage
Water
leakage
Ditch
Less than
50mm gap
Water
leakage
Drain pan
Drain
hose
Leakage
checking
Connecting area
drain hose
Leakage
checking
Service Manual 25
Installation
CAUTION:
To avoid nitrogen entering the
refrigerant system in a liquid state, the top of
the cylinder must be higher than its bottom when you
pressurize the system. Usually, the cylinder is used
in a vertical standing position.
Air and moisture remaining in the refrigerant system
have undesirable effects as indicated below.
• Pressure in the system rises.
• Operating current rises.
• Cooling(or heating) efficiency drops.
• Moisture in the refrigerant circuit may freeze and
block capillary tubing.
• Water may lead to corrosion of parts in the refrigeration system.
Therefore, the refrigerant system must be leak tested and evacuated to remove any noncondensables
and moisture from the system.
1. Preparation
• Check that each tube(both liquid and gas side
tubes) between the indoor and outdoor units have
been properly connected and all wiring for the test
run has been completed. Remove the service
valve caps from both the gas and the liquid side on
the outdoor unit. Note that both the liquid and the
gas side service valves on the outdoor unit are
kept closed at this stage.
2. Leak test
• Connect the manifold valve(with pressure gauges)
and dry nitrogen gas cylinder to this service port
with charge hoses.
• Pressurize the system to no more than 150
P.S.I.G. with dry nitrogen gas and close the cylinder valve when the gauge reading reached 150
P.S.I.G. Next, test for leaks with liquid soap.
• Do a leak test of all joints of the tubing(both indoor
and outdoor) and both gas and liquid side service
valves.
Bubbles indicate a leak. Be sure to wipe off the
soap with a clean cloth.
• After the system is found to be free of leaks,
relieve the nitrogen pressure by loosening the
charge hose connector at the nitrogen cylinder.
When the system pressure is reduced to normal,
disconnect the hose from the cylinder.
Lo
Hi
Indoor unit
Outdoor unit
Manifold valve
Charge hose
Nitrogen gas
cylinder(in vertical
standing position)
Pressure
gauge
CAUTION:
Be sure to use a manifold valve
for air purging. If it is not available, use a stop
valve for this purpose. The "Hi" knob of the manifold
valve must always be kept close.
Air Purging
Air Purging with Vacuum Pump
26 Room Air Conditioner
Installation
3. Evacuation
• Connect the charge hose end described in the preceding steps to the vacuum pump to evacuate the
tubing and indoor unit.
Confirm the "Lo" knob of the manifold valve is
open. Then, run the vacuum pump.
The operation time for evacuation varies with tubing length and capacity of the pump. The following
table shows the time required for evacuation.
• When the desired vacuum is reached, close the
"Lo" knob of the manifold valve and stop the vacuum pump.
4. Finishing the job
• With a service valve wrench, turn the valve stem of
liquid side valve counter-clockwise to fully open
the valve.
• Turn the valve stem of gas side valve counterclockwise to fully open the valve.
• Loosen the charge hose connected to the gas side
service port slightly to release the pressure, then
remove the hose.
• Replace the flare nut and its bonnet on the gas
side service port and fasten the flare nut securely
with an adjustable wrench. This process is very
important to prevent leakage from the system.
• Replace the valve caps at both gas and liquid side
service valves and fasten them tight.
This completes air purging with a vacuum pump.
The air conditioner is now ready to test run.
(1) Remove the caps from the 2-way and 3-way
valves.
(2) Remove the service-port cap from the 3-way valve.
(3) To open the 2-way valve turn the valve stem coun-
terclockwise approximately 90°, wait for about 2~3
sec, and close it.
(4) Apply a soap water or a liquid neutral detergent on
the indoor unit connection or outdoor unit connec-
tions by a soft brush to check for leakage of the
connecting points of the piping.
(5) If bubbles come out, the pipes have leakage.
Soap water method
Required time for evacuation when 30 gal/h vacuum pump is
used
10 min. or more 15 min. or more
If tubing length is less than 10m
(33 ft)
if tubing length is longer than 10m
(33 ft)
Gas side
Liquid side
Cap
Hexagonal wrench
3-way valve
(Close)
3-way valve
(Close)
2-way valve
(Open)
2-way valve
(Open)
Indoor unit
Outdoor unit
Lo Hi
Manifold valve
Vacuum pump
Pressure
gauge
Open
Close
Service Manual 27
Test Running
1. Check that all tubing and wiring have been properly
connected.
2. Check that the gas and liquid side service valves are
fully open.
Prepare remote controller
1. Remove the battery cover
by pulling it according to the
arrow direction.
2. Insert new batteries making
sure that the (+) and (–) of
battery are installed correctly.
3. Reattach the cover by
pushing it back into position.
• Use 2 AAA(1.5volt) batteries. Do not use
rechargeable batteries.
• Remove the batteries from the remote
control if the system is not going to be
used for a long time.
Settlement of outdoor unit
• Anchor the outdoor unit with a bolt and
nut(ø10mm) tightly and horizontally on a concrete
or rigid mount.
• When installing on the wall, roof or rooftop, anchor
the mounting base securely with a nail or wire
assuming the influence of wind and earthquake.
• In the case when the vibration of the unit is conveyed to the hose, secure the unit with an antivibration bushing.
Evaluation of the performance
Operate unit for 15~20 minutes, then check the system
refrigerant charge:
1. Measure the pressure of the gas side service valve.
2. Measure the temperature of the intake and discharge
of air.
3. Ensure the difference between the intake temperature and the discharge is more than 8°C(46°F)
(Cooling) or (Heating).
4. For reference; the gas side pressure of optimum
condition is as below.(Cooling)
If the actual pressure is higher than shown,
the system is most likely over-charged, and
charge should be removed. If the actual pressure are lower than shown, the system is
most likely undercharged, and charge should
be added.
The air conditioner is now ready for use.
NOTICE
NOTICE
Bolt
Tubing connection
Discharge
temperature
Discharge air
Intake temperature
R-22 35°C (95°F) 4~5kg/cm2G(56.8~71.0 P.S.I.G.)
R-410A 35°C (95°F) 8.5~9.5kg/cm
2
G(120~135 P.S.I.G.)
Outside ambient
TEMP.
Refrigerant
The pressure of the gas side
service valve.
This is performed when the unit is to be relocated
or the refrigerant circuit is serviced.
Pump Down means collecting all refrigerant in the
outdoor unit without loss in refrigerant gas.
CAUTION:
Be sure to perform Pump Down procedure with the
unit cooling mode.
Pump Down Procedure
1. Connect a low-pressure gauge manifold hose to
the charge port on the gas side service valve.
2. Open the gas side service valve halfway and purge
the air from the manifold hose using the refrigerant
gas.
3. Close the liquid side service valve(all the way in).
4. Turn on the unit's operating switch and start the
cooling operation.
5. When the low-pressure gauge reading becomes 1
to 0.5kg/cm2 G(14.2 to 7.1 P.S.I.G.), fully close the
gas side valve stem and then quickly turn off the
unit. At that time, Pump Down has been completed
and all refrigerant gas will have been collected in
the outdoor unit.
PUMP DOWN
Installation
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