LG S18AN, AS-W126RGH1, AS-W186TGH1 Schematic

Room

Air Conditioner

SERVICE MANUAL

MODELS: AS-W096QGG1

AS-W126RGH1 AS-W186TGH1 AS-W246TGH1 AS-W246TLG1

CAUTION

website http://www.lgservice.com

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

• ONLY FOR AUTHORIZED SERVICE PERSONNEL.

2 Room Air Conditioner

Air Conditioner Service Manual

TABLE OF CONTENTS

LG Model Name...............................................................................................................................................3

Safety Precautions..........................................................................................................................................5

Dimensions .....................................................................................................................................................9

Symbols Used in this Manual.....................................................................................................................9

Indoor Unit..................................................................................................................................................9

Outdoor Unit.............................................................................................................................................10

Product Specifications ................................................................................................................................12

Installation.....................................................................................................................................................14

Select the Best Location .........................................................................................................................14

Piping Length and Elevation.....................................................................................................................14

How to Fix Installation Plate.....................................................................................................................15

Drill a Hole in the Wall..............................................................................................................................15

Installation Instructions of Telephone Control(Optional)...........................................................................15

Flaring Work.............................................................................................................................................16

Connection of Piping Indoor.....................................................................................................................17

Connection of the Pipes-Outdoor.............................................................................................................20

Connect the Cable to the Indoor Unit.......................................................................................................21

Connect the Cable to the Outdoor Unit....................................................................................................22

Checking the Drainage.............................................................................................................................23

Form the Piping........................................................................................................................................23

Air Purging ...............................................................................................................................................24

Air Purging with Vacuum Pump................................................................................................................24

Test Running............................................................................................................................................26

Functions ......................................................................................................................................................27

Operation ......................................................................................................................................................30

Disassembly..................................................................................................................................................45

Indoor Unit................................................................................................................................................45

Schematic Diagram.......................................................................................................................................48

Electric Control device..............................................................................................................................48

Wiring Diagram.........................................................................................................................................51

Components Location ..............................................................................................................................53

Troubleshooting Guide.................................................................................................................................57

Refrigeration Cycle Diagram....................................................................................................................57

Pipe Length and the Elevation .................................................................................................................58

2-way, 3-way Valve...................................................................................................................................59

Cycle Parts...............................................................................................................................................66

Self-diagnosis Function............................................................................................................................67

Electronic Parts........................................................................................................................................69

Exploded View ..............................................................................................................................................80

Indoor Unit................................................................................................................................................80

Outdoor Unit.............................................................................................................................................81

Replacement Parts List ................................................................................................................................82

Indoor.......................................................................................................................................................82

Outdoor ....................................................................................................................................................83

Service Manual 3

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 U: China R410A

X: Mexico K: Turkey R22

V: Vietnam

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 A~Z Name of Chassis of Unit

Ex. LSP → SP Chassi

8 Look A~Z Look,

Color (Artcool Model)

9 Function A~Z

10 Serial No. 1~9 LG Model Development Serial No.

* ARTCOOL COLOR

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/changeove)+A/clean+Low A G Nano Plasma F+(A/changeove)+A/clean+4way+Low A H Tele+LED+4way I Internet J Plasma F+4Way+Oxy generator K Nano Plasma F+(A/changeove)+A/clean L Nano Plasma F+(A/changeove)+A/clean+4way M Nano Plasma F+(A/changeove)+A/clean+PTC N Nano Plasma F+(A/changeove)+Autoclean+4way+PTC P Nano Plasma F+(A/changeove)+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/changeove)+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 B Blue D Wood M Metal C Cherry

N Walnut A Gogh S Sisley Q Quran K Mecca

CHASSIS Look

D K L G M N D P

Division Panel Type(Deluxe) Fighting 'Look' (LG1) (LG2)-SEMI PANEL OEM1 OEM2 Panel Type(Deluxe) LG3

S4/S5

S6 SQ SR ST

2003~

4 Room Air Conditioner

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 M: Mexico K: Turkey R22 V: Vietnam 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 A~Z Name of Chassis of Unit

Ex. LSP → SP 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.

Nano Plasma F+4Way+(A/changeove)+A/clean+ U

R Mirror W White B Blue D Wood M Metal C Cherry

2003

Service Manual 5

Safety Precautions

To prevent injury to the user or other people and property damage, the following instructions must be followed.

■ Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications.

■ Meanings of symbols used in this manual are as shown below.

This symbol indicates the possibility of death or serious injury. This symbol indicates the possibility of injury or damage to properties only.

Be sure not to do.

Be sure to follow the instruction.

Do not use damaged power cords, plugs, or a loose socket.

• There is risk of fire or electric

shock.

Always use the power plug and socket with the ground terminal.

• There is risk of electric shock.

Install the panel and the cover of control box securely.

• There is risk of fire or electric shock.

■ Installation

Do not modify or extend the power cord.

• There is risk of fire or electric shock.

Do not install, remove, or reinstall the unit by yourself (customer).

• There is risk of fire, electric shock, explosion or injury.

Be cautious when unpacking and installing the product.

• Shape edges could cause injury. Be especially careful of the sharp edges.

6 Room Air Conditioner

Safety Precautions

For installation, always contact the dealer or an Authorized Service Center.

• There is risk of fire, electric shock, explosion, or injury.

Do not install the product on a defective installation stand.

• It may cause injury, accident, or damage to the product.

Be sure the installation area does not deteriorate with age.

• If the base collapses, the air conditioner could fall with it, causing property damage, product failure, and personal injury.

Do not let the air conditioner run for a long time when the humidity is very high and a door or a window is left open.

• Moisture may condense and wet or damage furnishings.

Always install a dedicated circuit and breaker.

• Improper wiring or installation may cause fire or electric shock

Use the correctly rated breaker or fuse.

• There is risk of fire or electric shock.

■ Operation

Do not turn the air-conditioner ON or OFF by plugging or unplugging the power plug.

• There is risk of fire or electric shock.

Use a dedicated outlet for this appliance.

• There is risk of fire or electric shock.

Grasp the plug to remove the cord from the outlet. Do not touch it with wet hands.

• There is risk of fire or electric shock.

Service Manual 7

Safety Precautions

■ Installation

Unplug the unit if strange sounds odors, or smoke comes from it.

• There is risk of fire, failure of the product, and/or electric shock.

Do not open the inlet grill of the product during operation. (Do not touch the electrostatic filter, if the unit is so equipped.)

• There is risk of physical injury, electric shock, or product.

Be cautious that water could not enter the product.

• There is risk of fire, electrical shock or product damage.

Do not place a heater or other appliances near the power cable.

• There is risk of fire, failure of the product, and/or electric shock.

Do not allow water to run into electric part.

• There is risk of fire, failure of the product, and/or electric shock.

Do not store of use flammable gas or combustibles near the air conditioner.

• There is risk of fire or failure of product.

Always check for gas(refrigerant) leakage after installation or repair of product.

• Low refrigerant levels may cause failure of product.

Install the drain hose to ensure that water is drained away properly.

• A bad connection may cause water leakage.

Keep level even when installing the product.

• To avoid vibration or water leakage.

Thinner

Wax

90˚

Safety Precautions

8 Room Air Conditioner

■ Operation

Use two or more people to lift and transport the air conditioner

• Avoid personal injury.

Use a soft cloth to clean. Do not use harsh detergents, solvents, etc.

• There is risk of fire, electric shock or damage to the plastic parts of the product.

Do not touch the metal parts of the product when removing the air filter. They are very sharp!

• There is risk of personal injury.

Do not step on or put anything on the product. (outdoor unit)

• There is risk of personal injury and failure of product.

Do not insert hands or other objects through the air inlet or outlet while the air conditioner is plugged in.

• There are sharp and moving parts that could cause personal injury.

Service Manual 9

Dimensions

Installation plate

W mm 824 900 1090

H mm 260 285 314 D mm 155 156 172

Model

Dimension

AS-W096QGG1 AS-W126RGH1

AS-W186TGH1 AS-W246TGH1

Indoor Unit

This symbol alerts you to the risk of electric shock. This symbol alerts you to hazards that could cause harm to the

air conditioner.

This symbol indicates special notes.

NOTICE

Symbols Used in this Manual

10 Room Air Conditioner

Outdoor Unit

Dimensions

Gas side (3-way valve)

Liquid side (2-way valve)

MODEL

DIM unit

W mm 770

H mm 540

D mm 245 L1 mm 285 L2 mm 65 L3 mm 518 L4 mm 10 L5 mm 100

AS-W096QGG1 AS-W126RGH1

Service Manual 11

Dimensions

Outdoor Unit

L7 L6 L8 L9

L10

L4L5

Gas side

Liquid side

AS-W186TGH1 AS-W246TGH1 AS-W246TLG1

W mm 870

H mm 655

D mm 320 L1 mm 370 L2 mm 340 L3 mm 25 L4 mm 630 L5 mm 25 L6 mm 546 L7 mm 162 L8 mm 162 L9 mm 54

L10 mm 74.5

MODEL

DIM

12 Room Air Conditioner

Product Specifications

Table-1

Model Name

Item Unit

MIN kcal/h.(W)

Btu/h.

Cooling Capacity Type kcal/h.(W)

Btu/h.

Max kcal/h.(W)

Btu/h.

MIN kcal/h.(W)

Btu/h.

Heating Capacity Type kcal/h.(W)

Btu/h.

Max kcal/h.(W)

Btu/h.

IN:20°C,Out: -10°C(Heater ON)

Btu/h.

IN:20°C,Out: -10°C(Heater OFF)

Btu/h.

Power Input Cooling W

Heating W Heating(-10°C,Heater ON)

Heating(-10°C,Heater OFF)

Running Current Cooling A

Heating A Heating(-10°C,Heater ON)

Heating(-10°C,Heater OFF)

Starting Current Cooling A

Heating A

EER Cooling W/W

Btu/h.W COP Heating W/W Power Supply Ø,V,Hz Power Factor % Air Circulation Indoor,Max m3/min(CFM)

Outdoor,Max m3/min(CFM) Moisture Removal l/h.(pts/h.) Noise Level Indoor,High dB(A)±3 (Sound Med. dB(A)±3 Pressure,1m) Low dB(A)±3

Outdoor,Max dB(A)±3 Refrigerant(R410A)Charge g Power Cord AWG#:P*mm

Connecting Cable AWG#:P*mm

Connecting Tube Liquid Side mm(in) (Ø. Socket Flare) Gas Side mm(in)

Length,std m(in) Drain Hose (O.D , I.D) mm(in)

Indoor mm Dimension inch (W*H*D) Outdoor mm

inch

Net Weight Indoor kg(lbs)

Outdoor kg(lbs)

AS-W096QGG1 AS-W126RGH1 AS-W186TGH1 AS-W246TGH1

Product Specifications

1,582 2,110 1,758 4,249 1,361 1,814 1,512 3,654 5,400 7,200 6,000 14,500 2,640 3,520 5,280 7,032 2,270 3,027 4,540 6,048 9,010 12,014 18,016 24,000 2,901 3,868 5,801 7,735 2,495 3,326 4,990 6,653 9,900 13,200 19,800 26,400 1,978 2,532 1,406 3,604 1,701 2,177 1,210 3,100 6,750 8,640 4,800 12,300 3,170 3,960 6,070 7,735 2,726 3,405 5,219 6,653

10,819 13,512 20,711 26,400

3,481 4,351 6,651 8,497 2,994 3,742 5,720 7,308

11,880 14,850 22,700 29,000

----

950 1,200 1,630 2,480

1,150 1,300 1,900 2,730

----

4.3 5.4 7.5 11.5

5.1 5.7 8.6 12.5

----

4.3 5.4 7.5 11.5

5.1 5.7 8.6 12.5

2.78 2.93 3.24 2.84

9.48 10.01 11.06 9.68

2.76 3.05 3.19 2.83

1,220-240,50 1,220-240,50 1,220-240,50 1,220-240,50

97 97 97 97

7.2(254) 8.70(307) 13.0(459) 16.0(565) 26(918) 26(918) 42(1483) 45(1589)

1.4(2.94) 1.5(3.2) 2.12(4.48) 2.90(6.13) 35 40 42 47 32 37 39 43 29 31 36 39 48 48 55 58

610 810 1180 1500 16:3*1.0 16:3*1.5 12:3*2.5 12:3*2.5 16:4*1.0 16:4*1.5 12:4*2.5 12:4*2.5

6.35(1/4) 6.35(1/4) 6.35(1/4) 9.52(3/8)

9.52(3/8) 12.7(1/2) 12.7(1/2) 15.88(5/8)

7.5(295) 7.5(295) 7.5(295) 7.5(295)

21.5,16.0(0.85,0.63) 21.5,16.0(0.85,0.63) 21.5,16(0.85,0.63) 21.5,16(0.85,0.63) 824*260*155 900*285*156 1090*314*172 1090*314*172

32.4*10.2*6.1 35.1*11.1*6.2 42.9*12.4*6.8 42.9*12.4*6.8 770*540*245 770*540*245 870*655*320 870*655*320

30.3*21.3*9.6 30.3*21.3*9.6 34.3*25.8*12.6 34.3*25.8*12.6

7.0(15.4) 9.5(20.9) 12(26.5) 12(26.5) 34(74.8) 38(83.8) 60(132.3) 65(143.3)

Service Manual 13

Product Specifications

Table-2

Model Name

Item Unit

MIN kcal/h.(W)

Btu/h.

Cooling Capacity Type kcal/h.(W)

Btu/h.

Max kcal/h.(W)

Btu/h.

MIN kcal/h.(W)

Btu/h.

Heating Capacity Type kcal/h.(W)

Btu/h.

Max kcal/h.(W)

Btu/h.

IN:20°C,Out: -10°C(Heater ON)

Btu/h.

IN:20°C,Out: -10°C(Heater OFF)

Btu/h.

Power Input Cooling W

Heating W Heating(-10°C,Heater ON)

Heating(-10°C,Heater OFF)

Running Current Cooling A

Heating A Heating(-10°C,Heater ON)

Heating(-10°C,Heater OFF)

Starting Current Cooling A

Heating A

EER Cooling W/W

Btu/h.W COP Heating W/W Power Supply Ø,V,Hz Power Factor % Air Circulation Indoor,Max m3/min(CFM)

Outdoor,Max m3/min(CFM) Moisture Removal l/h.(pts/h.) Noise Level Indoor,High dB(A)±3 (Sound Med. dB(A)±3 Pressure,1m) Low dB(A)±3

Outdoor,Max dB(A)±3 Refrigerant(R410A)Charge g Power Cord AWG#:P*mm

Connecting Cable AWG#:P*mm

Connecting Tube Liquid Side mm(in) (Ø. Socket Flare) Gas Side mm(in)

Length,std m(in) Drain Hose (O.D , I.D) mm(in)

Indoor mm Dimension inch (W*H*D) Outdoor mm

inch

Net Weight Indoor kg(lbs)

Outdoor kg(lbs)

AS-W246TLG1

4249 3654

14500

7032 6048

24000

7735 6653

26400

3604 3100

12300

7735 6653

26400

8497 7308

29000

2320 2400

11.5

12.5

11.5

12.5

2.61

10.34

3.22

1,220-240,50

16.0(565) 42(1589)

2.9 45

37 56

1500 12:3*2.5 12:4*2.5

9.52(3/8)

15.88(5/8)

7.5(295)

21.5,16(0.85,0.63) 1090*314*172

42.9*12.4*6.8 870*655*320

34.3*25.8*12.6 12(26.5)

60(132.3)

14 Room Air Conditioner

Installation

Indoor unit

• Do not have any heat or steam near the unit.

• Select a place where there are no obstacles in

front of the unit.

• Make sure that condensation drainage can be conveniently routed away. Do not install near a doorway.

• Ensure that the space around the left and right of the unit is more than "A". The unit should be installed as high on the wall as possible, allowing a minimum of "B" from ceiling.

• Use a stud finder to locate studs to prevent unnecessary damage to the wall.

Outdoor unit

• 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.

• 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.

• Do not place animals and plants in the path of the warm air.

• Take the air conditioner weight into account and select a place where noise and vibration are minimum.

• Select a place so that the warm air and noise from the air conditioner do not disturb neighbors.

More than "A"

More than B

More than 2.3m

More than "B"

More than 10cm More than 10cm

More than 60cm

More than 70cm

CAUTION: Install the indoor unit on the wall

where the height from the floors more than 2.3 meters.

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.

Grade

Clearance(cm)

7K~28K 10 5

30K~38K 30 12

Pipe Size

Capacit

(Btu/h)

GAS LIQUID

Max.

Length

A (m)

Additional

Refrigerant

(g/m)

Max.

Elevation

B (m)

Standard

Length

(m)

7k~14k

3/8"(Ø9.52) 1/4"(Ø6.35) 4 or 7.5 7 15 20 1/2"(Ø12.7) 1/4"(Ø6.35) 4 or 7.5 7 15 20 1/2"(Ø12.7) 1/4"(Ø6.35) 4 or 7.5 15 30 20

18k~28k 5/8"(Ø15.88) 1/4"(Ø6.35) 4 or 7.5 15 30 20

5/8"(Ø15.88) 3/8"(Ø9.52) 4 or 7.5 15 30 30

30k~38k

5/8"(Ø15.88) 3/8"(Ø9.52) 7.5 15 30 30 3/4"(Ø19.05) 3/8"(Ø9.52) 7.5 15 30 50

If case more than 5m

Outdoor unit

Indoor unit

Outdoor unit

Indoor unit

Oil trap

Outdoor unit

Indoor unit

Selection of the Best Location

Piping Length and Elevation

Service Manual 15

Installation

The wall you select should be strong and solid enough to prevent vibration

1. Mount the installation plate on the wall with four 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.

• 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.

• Open the Front Grille.

• Pass Telephone Control Cord Wire through the

hole which the power cord goes through.

• Connect Telephone Control Cord Wire to the phone jack of telephone PCB of Control Box.

• Fix Telephone Control Cord Wire inside Control box so as not to disconnect.

• Close the Front Grille.

Installation Plate

Type "A" screw

5-7mm

(3/16"~5/16")

Indoor

WALL

Outdoor

Answering telephone / Normal telephone

(Not packed in the box)

Adaptor

(Not packed in

the box)

Telephone Control

Cord Wire

(Packed in the box)

Phone Conductor

Installation plate

Ø70mm

Left rear piping Right rear piping

Ø70mm

Left rear piping

Right rear piping

CE A

Installation plateInstallation plate

ABCD

SJ 90 20 80 20

SL, SK 45 40 80 20

SQ 75 12 80 12 SR 0 40 20 40 ST 105 0 210 0

CHASSIS

(Grade)

Distance (mm)

How to Fix Installation Plate Drill a Hole in the Wall

Installation Instructions of Telephone Control(Optional)

ABCDE SM 180 115 - 115 50 SN 180 115 195 115 -

CHASSIS

(Grade)

Distance (mm)

16 Room Air Conditioner

Installation

Flaring Work

Main cause for refrigerant leakage is due to defect in the flaring work. Carry out correct flaring work using the following procedure.

Cut the pipes and the cable.

• Use the piping kit accessory or pipes purchased locally.

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

• Cut the pipes a little longer than the measured distance.

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

Burr removal

• Completely remove all burrs from the cut cross section of pipe/tube.

• 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

• Firmly hold copper pipe in a die in the dimension shown in the table above.

• Carry out flaring work using flaring tool as shown below.

Check

• Compare the flared work with figure below.

• If flare is noted to be defective, cut off the flared

section and re-flare it.

Copper

pipe

90°

Slanted Uneven Rough

Bar

Copper pipe

Clamp handle

Red arrow mark

Cone

Yoke

Handle

Bar

"A"

Inclined

Inside is shiny without scratches

Smooth all round

Even length

all round

Surface

damaged

Cracked Uneven

thickness

= Improper flaring =

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

Service Manual 17

Installation

Connection of Piping Indoor

• Preparing the indoor unit's piping and drain hose for installation through the wall.

• Remove the plastic tubing retainer(see illustration below) and pull the tubing and drain hose away from chassis.

• Replace the plastic tubing holder in the original position.

For right rear piping

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

connection 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 upper side can cause drain pan to overflow inside the unit.

If the drain hose is routed inside the room, insulate the hose with an insulation material* so that dripping from "sweating"(condensation) will not damage furniture or floors.

*Foamed polyethylene or equivalent is recom-

mended.

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).

4. Connecting the pipings to the indoor unit and drain hose to drain pipe.

• Align the center of the pipes and sufficiently tighten the flare nut by hand.

NOTICE

CAUTION:

When install, make sure that the remaining

parts must be removed clearly so as not to damage the piping and drain hose, especially power cord and connecting cable.

Tubing holder

Connecting cable

Loop

Gas side piping

Liquid side piping

Drain hose

Connecting

cable

Indoor unit tubing Flare nut Pipes

Drain hose

18 Room Air Conditioner

Installation

• Tighten the flare nut with a wrench.

• When extending the drain hose at the indoor unit,

install the drain pipe.

5. Wrap the insulation material around the connecting portion.

• Overlap the connection pipe insulation material

and the indoor unit pipe insulation material. Bind them together with vinyl tape so that there is no gap.

• Wrap the area which accommodates the rear piping housing section with vinyl tape.

• 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.

For left rear piping

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.

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

Wrench

Indoor unit tubing

Open-end wrench (fixed)

Connection pipe

Flare nut

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

Drain hose

Connecting

cable

Drain pipe

Connecting cable

Service Manual 19

Installation

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 cable.

• Connecting cable

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.

6. Connecting the pipings to the indoor unit and the drain hose to drain pipe.

• Align the center of the pipes and sufficiently tight-

en the flare nut by hand.

• Tighten the flare nut with a wrench.

• When extending the drain hose at the indoor unit,

install the drain pipe.

7. Wrap the insulation material around the connecting portion.

• Overlap the connection pipe heat insulation and the indoor unit pipe heat insulation material. Bind them together with vinyl tape so that there is no gap.

• Wrap the area which accommodates the rear piping housing section with vinyl tape.

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

Vinyl tape

Adhesive

Drain hose

Indoor unit drain hose

(narrow)

Plastic bands

Insulation material

Vinyl tape(narrow)

Connection pipe

Connecting cable

Indoor unit piping

Pipe

Vinyl tape (wide)

Wrap with vinyl tape

Installation plate

Spacer

Indoor unit

8cm

Indoor unit tubing Flare nut Pipes

Wrench

Indoor unit tubing

Connection pipe

Flare nut

Open-end wrench (fixed)

20 Room Air Conditioner

Installation

• 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.

8. Reroute the pipings and the drain hose across the back of the chassis.

9. Set the pipings and the drain hose to the back of the chassis with the tubing holder.

• Hook the edge of tubing holder to tap on chassis and push the bottom of tubing holder to be engaged at the bottom of chassis.

10. Indoor unit installation

• Remove the spacer.

• 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).

1. Align the center of the pipings and sufficiently tighten the flare nut by hand.

2. 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

Drain hose

Vinyl tape(narrow)

Pipe

Wrap with vinyl tape(wide)

Piping for passage through piping hole

Outdoor unit

Gas side piping (Bigger diameter)

Liquid side piping (Smaller diameter)

Torque wrench

Tubing holder

Drain hose

Connecting

cable

Connection of the Pipes-Outdoor

Service Manual 21

Installation

• Connect the cable to the indoor unit by connecting the wires to the terminals on the control board in 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.)

The earth wire should be longer than the common wires.

Air

Conditioner

Main power source

Circuit Breaker

Use a circuit breaker or time delay fuse.

CAUTION

The power connecting cable connected to the indoor and outdoor unit should be complied with the following specifications (Type "B" approved by HAR or SAA).

The power cord connected to the "A" unit should be complied with the following specifications(Type "B" approved by HAR or SAA).

7k, 9k 12k 18k

1.0 1.5 2.5

NORMAL CROSS

-SECTIONAL AREA

Grade

7k, 9k 12k 18k

1.0 1.5 2.5

NORMAL CROSS

-SECTIONAL AREA

Grade

(mm2)

(mm

)

CAUTION:

• The above circuit diagram is subject to change without notice.

• Be sure to connect wires according to the wiring diagram.

• Connect the wires firmly, so that not to be pulled out easily.

• Connect the wires according to color codes by referring the wiring diagram.

• When installing, refer to the circuit diagram on the Control Box of Indoor Unit.

• When installing, refer to the wiring diagram on the Control Cover Inside Outdoor Unit.

Connect the Cable to the Indoor Unit.

CAUTION:

If a power plug is not to be used, provide a circuit breaker between power source and the unit as shown below.

22 Room Air Conditioner

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

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 20))

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

7k~14k 18k 24k~28k 30k, 32k 36k, 38k

15 20 30 30 40

Circuit

Breaker

(A)

Grade

Connect the Cable to the Outdoor Unit

Service Manual 23

Installation

Checking the Drainage Form the Piping

1. To remove the front panel from the indoor unit.

• Set the air direction louvers up-and-down to the

position(horizontally) by hand.

• Remove the securing screws that retain the front

panel. Pull the lower left and right sides of the grille toward you and lift it off.

2. To check 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.

3. Drain piping

• The drain hose should point downward for easy

drain flow.

• Do not make drain piping.

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.

Pull the right and the left side.

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

Downward slope

Do not raise

Accumulated drain water

Tip of drain hose dipped in water

Air

Waving

Water leakage

Ditch

Less than 50mm gap

Water leakage

24 Room Air Conditioner

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 indoor unit and tubing between the indoor and outdoor unit 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.

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

Service Manual 25

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

2-way valve

(Open)

3-way valve

(Close)

Indoor unit

Pressure gauge

Open

Outdoor unit

Manifold valve

Lo Hi

Vacuum pump

26 Room Air Conditioner

Installation

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 control

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

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

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

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