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SERVICE MANUAL
MODEL: LP-K Series
Contents
Functions Product Specifications Dimensions Refrigeration Cycle Diagram Wiring Diagram Operation Details Installation of Indoor, Outdoor Unit Test Running 3-way Valve Cycle Troubleshooting Guide Electronic Parts Troubleshooting Guide Electronic Control Device Schematic Diagram Exploded View and Replacement Parts List 3 6 7 7 8 12 19 30 32 38 39 42 43 44
Functions
Indoor Unit
Power Switch ON/OFF Operation Mode Control Cooling, Heating, Soft Dry, Fan Indoor Fan Speed Control High, Low Jet Cool Speed Cooling operates super high fan speed in cooling mode Energy Saving Cooling Mode only Room Temperature control Maintains the room temperature in accordance with the Setting Temp. Up: up to 30C Down: down to 16C Sensing Heat Exchanger Temperature Heat exchanger temperature sensor (Thermistor)
Soft Dry Operation Mode Intermittent operation of fan at low speed. Time Delay Safety Control Restarting is inhibited for approx. 3 minutes. Fan Operation Used to circulate room air without cooling. AutoRestart The power comes on again after a power failure. 3
Remote Control
Heating Operation Mode Sot Dry Operation Mode Intermittent operation of fan at low speed. Fan Operation Used to circulate room air without cooling. Timer Control OFF Timer (1, 2, 3,......7 hour) Jet Cool Speed cooling operates super high fan speed in cooling mode. Energy Saving
Airflow Direction Control Airflow direction Auto-swing and Manual Contol. Room Temperature Control Up: up to 30C Down: down to 16C
Outdoor Unit
Deice Control De-ice PCB Outdoor Fan Speed Control One speed Sensing Heat Exchanger Temperature Heat exchanger temperature sensor (Thermistor) Sensing Discharge Pressure For Compressor Discharge pressure sensor (High Pressure Switch)
Product Specifications
HEAT PUMP MODELS
MODEL ITEMS POWER SUPPLY , V, Hz COOLING CAPACITY HEATING CAPACITY (Incl. elec. Heater) POWER INPUT COOLING HEATING RUNNING CURRENT COOLING HEATING MODEL MAKER TYPE COMPRESSOR CAPACITY INPUT LRA NOISE LEVEL INDOOR OUTDOOR AIR CIRCULATION INDOOR OUTDOOR Btu/hr (KW) A dB(A) dB(A) CFM/CMM CFM/CMM OZ(kg) R/C/FPI R/C/FPI TYPE TYPE Btu/hr Btu/hr W W A A UNIT 1, 220-240, 50 27,800 27,800 + (2kw) 2,750 2,450 12.5 11.2 H23B33SABHA BRISTOL RECIPRO 28,300 2.76 76 48 58 670/19 2,225/63 88.1(2.5) 3/22/18 2/30/16 SIROCO PROPELLER MICOM CONTROL 19.68(500) inch(mm) 70.86(1800) 12.59(320) 34.25(870) inch(mm) 31.49(800) 12.59(320) Ib(kg) Ib(kg) inch(mm) inch(mm) 88.18(40) 143.2(65) 3/8"(9.52) 5/8"(15.88) 1, 220,60 27,800 27,800 3,400 3,200 16 14.5 AWG5532EXN TELUMSEH RECIPRO 31,500 3.3 90 48 58 670/19 2,225/63 82.9(2.35) 3/22/18 2/30/16 SIROCO PROPELLER MICOM CONTROL 19.68(500) 70.86(1800) 12.59(320) 34.25(870) 31.49(800) 12.59(320) 88.18(40) 143.2(65) 3/8"(9.52) 5/8"(15.88) LP-K3063ZA/ZL/HA/HB/HL/HM LP-K3023HA/HL
ROOM TEMPERATURE CONTROL D I M E N S I O N S WIDTH INDOOR HEIGHT DEPTH WIDTH OUTDOOR HEIGHT DEPTH INDOOR OUTDOOR CONNECTIONS LIQUID GAS
NET WEIGHT
Product Specifications
COOLING ONLY MODEL
MODEL ITEMS POWER SUPPLY , V, Hz COOLING CAPACITY HEATING CAPACITY (Incl. elec. Heater) POWER INPUT COOLING HEATING RUNNING CURRENT COOLING HEATING MODEL MAKER TYPE COMPRESSOR CAPACITY INPUT LRA NOISE LEVEL INDOOR OUTDOOR AIR CIRCULATION INDOOR OUTDOOR Btu/hr (KW) A dB(A) dB(A) CFM/CMM CFM/CMM OZ(kg) R/C/FPI R/C/FPI TYPE TYPE Btu/hr Btu/hr W W A A UNIT 1, 220-240, 50 20,000 1,900 9 FX24QP12CA LG SCROLL 20,000 1.94 53 45 53 600/17 2,046/58 55(1.56) 2/22/18 2/24/18 SIROCO PROPELLER MICOM CONTROL 19.68(500) inch(mm) 70.86(1800) 12.59(320) 34.25(870) inch(mm) 25.78(655) 12.59(320) Ib(kg) Ib(kg) inch(mm) inch(mm) 88.18(40) 138.6(63) 1/4"(6.35) 5/8"(15.88) LP-K2063CA/CL/AA LP-K3023CA/CL/ CM/AA 1, 220,60 27,800 3,400 16 AWG5532EXN TECUMSHE RECIPRO 31,500 3.3 90 48 58 670/19 2,046/58 63.5(1.8) 3/22/18 2/24/18 SIROCO PROPELLER MICOM CONTROL 19.68(500) 70.86(1800) 12.59(320) 34.25(870) 25.78(655) 12.59(320) 88.18(40) 138.6(63) 3/8"(9.52) 5/8"(15.88) LP-K3063CA/CL/ CM/AA 1, 220-240, 50 27,800 2,850 13 H23B33SABHA BRISTOL RECIPRO 28,300 2.76 76 48 58 670/19 2,046/58 60.0(1.7) 3/22/18 2/24/18 SIROCO PROPELLER MICOM CONTROL 19.68(500) 70.86(1800) 12.59(320) 34.25(870) 25.78(655) 12.59(320) 88.18(40) 138.6(63) 3/8"(9.52) 5/8"(15.88) LP-K4023CA/CL/AA 1, 220,60 36,000 3,500 17 CR38K6-PFV-502 COPELAND RECIPRO 38,200 3.52 102 52 62 741/21 2,225/63 84.6(2.4) 3/22/18 2/30/18 SIROCO PROPELLER MICOM CONTROL 19.68(500) 70.86(1800) 12.59(320) 34.25(870) 31.49(800) 12.59(320) 88.18(40) 147.7(67) 3/8"(9.52) 5/8"(15.88)
ROOM TEMPERATURE CONTROL D I M E N S I O N S WIDTH INDOOR HEIGHT DEPTH WIDTH OUTDOOR HEIGHT DEPTH INDOOR OUTDOOR CONNECTIONS LIQUID GAS
NET WEIGHT
Dimensions
Indoor Unit Outdoor Unit
Air Outlet Vent Remote Signal Receptor Air Intake Vent (Rear)
OUTDOOR UNIT
CHECK VALVE
COMPRESSOR
Wiring Diagram
(1) LP-K3063ZA/ZL/HA/HL/HM/ZM
WIRING DIAGRAM
OUTDOOR UNIT INDOOR UNIT 1 2
POWER SUPPLY BK BR BR BL BR BL 4 8 1 2 6 0 WH BL BR PIPE TH BR FUSE(250V,5A) BK BK BL
FUSE
BK YL T/B1 T/B2
(250V/3.15L)
OR WH BK BL RD
S R
FAN
MOTOR BK HIGH PRESS SWITCH BK
COMP
REVERSING VALVE
RY-AIRC
RD BL
OR
CAPACITOR YL
SUMP HEATER
RY-COMP
CAPACITOR
OR
WH
EVAP TH
BK
BL BL BK FUSE(250V,5A) GN/YL
CN1
ROOM TH
NOTE
BL : BK : BR : RD : BLUE BLACK BROWN RED OR : ORANGE WH : WHITE YL : YELLOW GN/YL : GREEN/YELLOW
: OPTIONAL PARTS
BK WH RD
RY-SYNC
RY-4WAY RY-EH
BR
BL
BL
4 2
8 6
1 0
REVERSING VALVE BR
BR
L3 L2 L1
BK WH BK BR BL BK BK TERMINAL BLOCK
BK
BK
POWER INPUT
TO INDOOR UNIT
3854AP2708X
BL
BL
1(L) 2(N)
SM
L1 L3
L2
POWER RELAY
3 4 5 6
3 4 5 6
ZA,HA (AIR CLEANER MODEL ONLY)
DOOR S/W
A/CL UNIT
: FIELD WIRING
P/No.;3854A20172A
BL YL
CAPACITOR
OR
COMP S
C
RD
CAPACITOR
FAN MOTOR
OR BK
YL TERMINAL BLOCK
(3) LP-K3063CA/CL/CM
INDOOR UNIT
GN/YL RD BL BR
CIRCUIT DIAGRAM
OUTDOOR UNIT
6 5 4 3
POWER INPUT
FUSE (250V/3.15L)
RY-COMP RY-SYNC SM
1 F1 BR BR BL
YL
Cr BR OR WH BK BL RD
F2
BL BR BL BR BK
0 1
OR
RY-AIRC
FAN MOTER
POWER RELAY
2 4
6 8
GN/YL
BL BL BK OR YL BR RD BL S R
BK
CN1
ROOM
NOTE
CAPACITOR
CAPACITOR
HVB ASM
BK WH RD
A/CL UNIT
BL : BLUE COMP. BK : BLACK BR : BROWN RD : RED OR : ORANGE WH: WHITE YL : YELLOW GN/YL:GREEN/YELLOW : OPTIONAL PARTS
FAN MOTOR
P/No.; 3854A20172B
(4) LP-K4023CA/CL/CM
CIRCUIT DIAGRAM
INDOOR UNIT
BK WH RD
OUTDOOR UNIT
BK WH RD
FUSE
RY-COMP (250V 3.15A) RY-SYNC
SM
FMo
Ci BK
OR YL
BR OR WH BK BL RD
Fan Motor
GN/YL
52C A B
DOOR S/W
CN-DISP(1) CN-DISP(2)
ROOM TH
EVAP TH
CM
BK
CN1 CN2
1 2 3
4 5 6
HVB ASM
BK WH RD
A/CL ASM
10
(5) LP-K3023HA/HL/HM
CIRCUIT DIAGRAM
INDOOR UNIT OUTDOOR UNIT
HIDDEN LINE: FIELD WIRING
NOTE
BL : BLUE BK : BLACK BR : BROWN RD : RED OR : ORANGE WH: WHITE YL : YELLOW GN/YL: GREEN/YELLOW : OPTIONAL PARTS
GN/YL BL RD BL BR
6 5 4 3
POWER INPUT
FUSE (250V/3.15L)
RY-COMP RY-REVERSING VALVE SM
1 F1 BR BR BL
YL
RY-SYNC
Cr BR OR WH BK BL RD
T/B2
BK
F2
BL
RY-AIRC
BR BL BL
L1 L2 L3
BK
0 1
2 4
6 8
GN/YL
BR BL
DEICER P.C.B OR
REVERSING VALVE
BK
CN1
BR RD BL BK OR YL S R
BK RD
CAPACITOR
CAPACITOR
A/CL UNIT
COMP.
FAN MOTOR
P/No.; 3854A20172C
(6) LP-K3023CA/CL/CM/AA
CIRCUIT DIAGRAM
INDOOR UNIT
GN/YL RD BL BR
OUTDOOR UNIT
6 5 4 3
POWER INPUT
FUSE (250V/3.15L)
RY-COMP RY-SYNC SM
1 F1 BR BR BL
YL
Cr BR OR WH BK BL RD
F2
BL BR BL BR BK
RY-AIRC
FAN MOTER
POWER RELAY
GN/YL
BL BL BK OR YL BR RD BL S R
BK
CN1
ROOM TH
NOTE
CAPACITOR
CAPACITOR
HVB ASM
BK WH RD
A/CL UNIT
BL : BLUE COMP. BK : BLACK BR : BROWN RD : RED OR : ORANGE WH: WHITE YL : YELLOW GN/YL:GREEN/YELLOW : OPTIONAL PARTS
FAN MOTOR
P/No.; 3854A20172D
11
Operation Details
(1) The function of main control
1. Time Delay Safety Control
3min 3sec 30sec The compressor is ceased for 3 minutes to balance the pressure in the refrigeration cycle. (Protection of compressor) The indoor fan is ceased for 3 seconds to prevent relay noise. (Protection of fan relay and micro chip) 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.
Intake Air temp. Setting Temp. +1C (Compressor ON) Setting Temp. -1C (Compressor OFF) More than 3 minutes Indoor Fan Speed Compressor Selecting fan speed ON Selecting fan speed OFF Selecting fan speed ON More than 3 minutes Selecting fan speed OFF Selecting fan speed ON
....
- If you select ' ', the Off-Timer function will be cancelled. - During Off-Timer Operation, if you repress the timer set button, the rest time will be displayed. 12
OFF
OFF
OFF
A point: The indoor pipe temperature to be less then 35C & Discharge air Temperature to be less than 29C. The indoor fan operates for minimum 10sec. even if falls lower than 34C. During heating operation, the operating procedure of the indoor fan is as the following.
Stop(VI) Low(V) Selecting Fan Speed(IV)
34C
28C 26C
Heating Start
Low(II)
Step
Indoor fan speed Off Low Selecting speed Selecting speed Low Off
OFF LOW ON
LOW OFF
OFF
OFF
ON
OFF
A point: The indoor pipe temperature to be less than BC. The indoor fan operates for minimum 10sec. even if the indoor pipe temperature falls lower than BC. During heating operation, the operating procedure of the indoor fan is as the following.
Stop(VI) Low(V) Selecting Fan Speed(IV)
Heat OFF
CC
32C 34C 36C 30C 31C 33C 28C 30C 32C 26C 28C 30C 27C 29C 31C -
DC
DC BC
(Hot-Start Release Point)
22C 20C
Heating Start
Low(II)
Step
14
6. Hot-Start Control
The indoor fan stops until the evaporator piping temperature will be reached to 28C. During heating operation, if piping temperatures fall below 26C fan stops. The operation diagram is as following.
Maximum 1min
OFF
LOW ON
OFF
7. 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 -6C 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 12C even if before 10 minutes. The second defrost starts only when the outdoor pipe temperature falls below -6C after 45 minutes pass from ending of the first defrost and more than.
Defrost
ON ON ON OFF
OFF ON ON
ON ON
OFF ON OFF
15
Operation Cooling
Dry operation
Cooling operation
3 min.
10 min.
maximum 7 min.
3 min.
maximum 10 min.
LOW OFF
LOW ON
LOW OFF
LOW OFF
LOW ON
LOW OFF
OFF
11. 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 CL (CL) 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. 16
27C 26C 25C 24C 23C 22C 21C 28min. 50min. Setting energy saving operation 35min. 50min. Setting temp. 23C 47min. 50min. Setting temp. 25C maintains setting temp. 25C
17
18
5cm 10 0cm
5cm 40cm
2) 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.
50c
50c
0cm 10
50c
MODEL
Max. Length GAS SIDE LIQUID SIDE A (m) 5/8" 5/8" 5/8" 1/4" 3/8" 3/8" 30 30 30
19
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.
200mm 70mm 90mm 70mm
Example) In case of 10m long pipe(one-way), the amount of refrigerant to be replenished is: (10 - 5) x 30 = 150g
INSIDE
Plastic tube (Bushing)
OUTSIDE
Wall
20
s Installation Method
1. Procedure
No. 1 2 Installation works Preparation of tools and installation parts Flaring the pipes Descriptions Preparation of installation To insert the flare nuts, mounted on the connection parts of both indoor and outdoor unit, onto the copper pipes. To reduce the flow resistance of refrigerant. Connection of long piping Connecting the pipings of the outdoor unit. To remove dust and scale in working. Connecting the pipings of the indoor unit.
3 4 5 6 7 8 9
Pipe bending Connection of installation parts (elbows, socket etc) Tighten the flare nut (outdoor) Blowing the pipings Tighten the flare nut (indoor) Check a gas-leakage of the connecting part of the pipings. 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 11 12 13 14 15 16
Open the 3-way (liquid side) and 3-way (gas side) valves. Form the pipings Checking the drainage (indoor unit) Connecting the cable between outdoor and indoor unit Connecting the main cable to outdoor unit Supply the power to the crankcase heater (Before the operating the unit) Cooling operation, Heating operation (Use the remote control or display of the indoor unit) To prevent the liquid back to the compressor. (Heat pump only) To prevent heat loss and sweat To ensure if water flow drain hose of indoor unit. Preparation of the operating
21
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Pliers (150mm) Tapeline Core drill Voltmeter, Amperemeter, Clampmeter Insulation resistance tester Glass thermometer Copper tubes Insulation material Tape Electrical Leakage Breaker Cable Drain hose sockets, elbows
Cutting the wires To measure the length To make holes through the concrete wall and blocks To measure the current and voltage To measure the insulation resistance To measure the intake and outlet air temperature of the indoor unit To use the connecting pipings To cover the connecting pipings To finish the connecting pipings To shut off the main power To connect the cable from outdoor unit to indoor unit To remote the condensing water
22
Pipe cutter
90
Slanted
Rough
Remove burrs. Remove burrs from cut edges of pipes. Turn the pipe end down to avoid the metal powder entering the pipe.
Pipe
Caution: If burrs are not removed, they may cause a gas leakage. Flaring the pipes. Insert the flare nuts, mounted on the connection ports of both indoor and outdoor unit, onto the copper pipes. Some refrigerant gas may leak, when the flare nuts are removed from the indoor unit, as some gas is charged to prevent the inside of the pipe from rusting. Fit the copper pipe end into the Bar of flare tool about 0~0.5mm higher. (See illustaration) Flare the pipe ends. Tape the flaring part to protect it from dust or damages.
Copper pipe Clamp handle Point down
Reamer
0~0.5mm Bar
Bar
= Improper flaring = 2 3
Inclined
Surface damaged
Cracked
Uneven thickness
23
2. Connection of piping
Move the indoor tubing and drain hose to the hole Remove tubing holder and pull the tubing out of the chassis. Replace the tubing holder into original position Route the tubing and the drain hose staight backwards. 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. Tape the tubing and the connecting cable. Indoor unit installation. 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. PIPE SIZE 3/8" 1/2" 5/8" 3/4" TORQUE 4.2 Kg.m 5.5 Kg.m 5.5 Kg.m 6.5 Kg.m
Flare nut
Pipings
Spanner
Torque wrench
3. Precautions in bending
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) Do not repeat the bending process to prevent the tubing from cracking or crushing. 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)
24
Knock-out holes
25
Outdoor unit
Liquid side piping
Torque wrench
CAUTION
Perform grounding
This product should be grounded. Defective grounding could cause an electric shock.
28K/30K/40K
2
CLAMP (10.7)
POWER SUPPLY
26
VOLTS
450/750V 450/750V
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. The starting voltage should be higher than 85% of the rated voltage marked on the name plate.
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)
UNIT
20K/30K/ 40K H/P C/O
Voltage Power source voltage working voltage Starting voltage Starting point Time
The screws 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 give rise to burn-out of the wires.) See to it that the starting voltage is maintained at more than 90 percent of the rated voltage marked on the name plate. The following troubles would be caused by voltage 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 insulation, type Ho7RNF approved by HAR or SAA) suitable for the product's electriccal capacity.
27
Check the drainage Pour a glass of water into the drain pan. Ensure if water flows drain hose of indoor unit.
28
Wrap the connecting port 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 water, and fix it on the wall to avoid swinging in the wind.)
In case the outdoor unit is installed below position of the indoor unit.
From the piping gathered by taping along the exterior wall fix it on the wall by saddle or equivalent.
In case the outdoor unit is installed upper position of the indoor unit.
In order to prevent water from entering the room, tape the piping from a trap. Fix the piping onto the wall with saddle or bracket.
;; ;; ;; ;; ;; ;;
29
Trap is required to prevent the electrical parts from entering the water.
Seal a small opening around the piping with gum type sealer. Trap
Trap
Drain water treatment of outdoor Unit(Heat Pump Only) When using the drain elbow hose, use a mount of 3cm of higher. In the cold district (0c continued for 2~3 days), the drain water is frozen and the fan fails to function, do not use the drain elbow.
Drain elbow Hose(inner diameter 20) Arrange the hose downward slope without waving.
Test running
1. PRECAUTIONS IN TEST RUN
The initial power supply must provide at least 90% of the rated voltage. Otherwise, the air conditioner should not be operated. Carry out the test run more than 5 minutes without fail. Caution (Test run will be cancelled 18 minutes later automatically) The test run is started by pressing the down room temperature checking button and ON/OFF button for 3 seconds at the same time. To cancel the test run, press ON/OFF button.
30
CAUTION
After the confirmation of the above conditions, prepare the wiring as follows: 1) Never fail to have an individual power specialized for the air conditioner. As for the method of wiring, be guided by the circuit diagram pasted on the inside of control box cover. 2) Provide a circuit breaker switch between power source and the unit. 3) 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 give rise to burn-out of the wires.) 4) Specification of power source 5) Confirm that electrical capacity is sufficient. 6) Be sure that the starting voltage is maintained at more than 90 percent of the rated voltage marked on the name plate. 7) Confirm that the cable thickness is as specified in the power sources specification. (Particularly note the relation between cable length and thickness.) 8) Never fail to equip a leakage breaker where it is wet or moist. 9) The following troubles would be caused by voltage 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. Proper starting power is not given to the compressor.
HAND OVER
Teach the customer the operation and maintenance procedures, using the operation manual (air filter cleaning, temperature control, etc.).
31
3-way Valve
1. Pump down
Indoor unit
Open
Outdoor unit
Gas side
Closed
3-Way valve
Lo
CLOSE CLOSE
Procedure
(1) Confirm that both liquid side and 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. (2) Operate the unit for 10 to 15 minutes. (3) Stop operation and wait for 3 minutes, then connect the charge set to the service port of the 3-way valve. Connect the charge hose to the service port. (4) Air purging of the charge hose. Open the low-pressure valve on the charge set slightly to air purge from the charge hose. (5) Set the liquid side valve to the closed position. (6) Operate the air conditioner in cooling mode and stop it when the gauge indicates 1kg/cm2g. (7) Immediately set the 3-way valve to the closed position. Do this quickly so that the gauge ends up indicating 3 to 5kg/cm2g. (8) Disconnect the charge set, and mount the 2way and 3-way valves stem nuts and the service port nut. Use torque wrench to tighten the service port nut to a torque of 1.8 kg.m. Be sure to check for gas leakage.
32
1) Re-airpurging
(Re-installation)
Indoor unit
Closed
Outdoor unit
Gas side
Closed
3-Way valve
Gas cylinder
Lo R22 OPEN
CLOSE
Procedure
(1) Confirm that both the liquid side valve and the gas side valve are set to the closed position. (2) Connect the charge set and a gas cylinder to the service port of the 3-way valve. Leave the valve on the gas cylinder closed. (3) Air purging. Open the valves on the gas cylinder and the charge set. Purge the air by loosening the flare nut on the 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. (4) Check for gas leakage. Check the flare connections for gas leakage. (5) Discharge the refrigerant. Close the valve on the gas cylinder and discharge the refrigerant until the gauge indicates 3 to 5 kg/cm2g. (6) Disconnect the charge set and the gas cylinder, and set the 2-way and 3-way valves to the open position. Be sure to use a hexagonal wrench to operate the valve stems. (7) Mount the valve stem nuts and the service port nut. Use torque wrench to tighten the service port nut to a torque of 1.8 kg.m. Be sure to check for gas leakage. * CAUTION: Do not leak the gas in the air during Air Purging.
33
Indoor unit
Open
Gas side
3-Way valve
Open
Lo
OPEN CLOSE
Procedure
(1) Confirm that both the liquid side and gas side valves are set to the back seat. (2) Connect the charge set to the 3-way valves port. Leave the valve on the charge set closed. Connect the charge hose to the service port. (3) Open the valve (Lo side) on the charge set and discharge the refrigerant until the gauge indicates 0 kg/cm2G. 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/cm 2 G. if this is the case, it will not be necessary to apply a evacuatin. Discharge the refrigerant gradually; if it is discharged too suddenly, the refrigeration oil will also be discharged.
34
2. Evacuation
(All amount of refrigerant leaked)
Indoor unit
Open
Gas side
3-Way valve
Open
Vacuum pump
Lo
OPEN CLOSE
Procedure
(1) Connect the vacuum pump to the center hose of charge set center hose (2) Evacuation for approximately one hour. Confirm that the gauge needle has moved toward -76 cmHg (vacuum of 4 mmHg or less). (3) Close 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). (4) Disconnect the charge hose from the vacuum pump. Vacuum pump oil. If the vacuum pump oil becomes dir ty or depleted, replenish as needed.
35
3. Gas Charging
(After Evacuation)
Indoor unit
Open
Outdoor unit
Gas side
Open
Check valve 3-Way valve
Charging cylinder Lo
(1) OPEN CLOSE
Procedure
\
(1) 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, also use a scale and reverse the cylinder so that the system can be charged with liquid. (2) Purge 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. (3) Open 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). 36
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. (4) Immediately disconnect the charge hose from the 3-way valves service port. Stopping par tway 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. (5) Mount the valve stem nuts and the service port nut. Use torque wrench to tighten the service port nut to a torque of 1.8 kg.m. Be sure to check for gas leakage.
2) Heating Mode
(After Evacuation)
Charging cylinder Lo (1) Check valve Liquid side Open 3-Way valve Outdoor unit OPEN CLOSE
Indoor unit
Procedure
(1) 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. (2) Purge 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. (3) Open 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). 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. (4) Immediately 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. (5) 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.
37
Temp. Difference
Operating Current
Temp. difference
: over 8C
Normal
Notice : Temperature difference between intake and discharge air depends on room air humidity. When the room air humidity is relativery higher, temperature difference is smaller. When the room air humidity is relatively lower temperature difference is larger. 2. Check temperature and pressure of refrigeration cycle. Suction pressure (Compared with the normal value) Temperature (Compared with the normal value) High Higher Normal
Cause of Trouble Defective compressor Defective 4-way reverse valve Excessive amount of refrigerant Insufficient amount of refrigerant (Leakage) Clogging
Description Current is low High pressure does not quickly rise at the beginning of operation Current is low Current is low
Lower
Higher
Notice : 1. The suction pressure is usually 4.5~6.0 kg/cm2G at normal condition. 2. The temperature can be measured by attaching the thermometer to the low pressure tubing and wrap it with putty.
38
Is the input voltage of transformer AC220V? YES Is the output voltage of transformer about AC14V? YES
NO
NO
NO
Check the main P.C.B pattern Exchange the transformer Check the D02D~D05D
Is the input voltage of IC01D DC14V? YES Is the output voltage of IC01D DC12V? YES
NO
NO
Exchange IC01D
NO
Exchange IC03D
NO
Possible Trouble 2
Is IC03M operated normally? YES Is the each Relay any problem? NO Check the fan motor and connector. (CN-MOTOR)
Exchange IC03M
39
YES
Is the input power AC220V (AC240V) at COMP magnetic coil contactor?
NO
NO NO
Is the unit operating?
YES
Check the COMP magnetic contactor of outdoor unit. Check the wiring connection
YES
Reset the power ON/OFF S/W ON
Is it heating mode?
NO
Select the heating operation mode.
YES
Room temp <Set temp?
NO
YES
Is the DC5V at 14 pin of terminal MICOM
NO
Replacement MICOM
YES
Is the DC5V at 18 pin of terminal MICOM
NO
Replacement MICOM
YES
Is the DC12V at each terminal? (RY-4WAY COIL)
NO
Replacement IC02M
YES
Is the AC220V (AC 240 V) between connector(4WAY) and CN-outunit of Main P.C.B
NO
Replacement RY-4WAY
YES
Is the DC12V at each terminal? (RY-COMP COIL)
NO
Replacement IC02M
YES
Is the AC220V (AC 240 V) between connector(CN-outunit) and of Main P.C.B
NO
Replacement RY-COMP
YES
Check the wiring diagram.
40
YES
NO
Compressor "ON"
YES
NO
YES
NO
YES
NO
Replacement MICOM
YES
NO
Replacement IC02M
YES
Is the AC220V (AC 240 V) between connector(HEATER) and CN-outunit of Main P.C.B
NO
Replacement RY-HEATER
YES
Check the heater wiring
41
42
Schematic Diagram
43
147582
146812
135313
152302 267110
266090 150170
44
135515
149750
336610
346810
359011
W0CZZ
352150
330870
130411
354211
45
1 1 1 1 1 1 1 1 1 1 1 1
46
Parts No. Location No. 135310 147581-1 147581-2 146812 147582 137211-1 137211-2 249310 268712 135313 135314 152302 150170 159830 66090 130411 135515 149750 336610 346810 359011 330860 352150 W0CZZ 330870 268714 249951 354211 267110 Parts Name FRAME DIFFUSERR ASSY LOUVER HORIZONTAL LOUVER HORIZONTAL SYNCHRONOUS MOTOR LOUVER VERTICAL PANEL FRONT ASSY PANEL FRONT SUB HOLDER DISPLAY ASSY DISPLAY PCB GRILLE INLET GRILLE INLET FILTER MAGNET ASSY A/CL UNIT ASSY SUPPORTER ASSY BASE ASSY TOP COVER GUIDE ASSY HOUSING ASSY MOTOR BLOWER DRAIN PAN DRAIN HOSE CAPACITOR DRAIN PAN ASSY MAIN PCB ASSY CONTROL BOX ASSY EVA COIL ASSY REMOCON LPK3023CA/CL/CM /AA 3531A10011C 4758A30003B 4758A30002C 2H01102A 3A01943C 3721A20057K 3721A20057L 3721A20007C 4931A30009B 6871A20222C 6871A20222D 3531AP2352J 5230AP3116A 4A70152B 5983AP1156C 4980AP1154A 3041A20003B 3551A30019B 4975AP3778A 3661AP2582A 4681AP2544E 3086AP1217A 5251AR1222J 3H00611C 3087AP2581A 6871A20213C 6871A20213D 4995A10049J 4995A10049K 5420AP2577E LPLPK4023CA/CL/CM K3063CA/CL/CM /AA 3531A10011C 3531A10011C 4758A30003B 4758A30002C 2H01102A 2H01102A 3A01943C 3721A20006P 3721A20057K 3721A20006N 3721A20057L 3721A20007C 3721A20007C 4931A20001S 4931A30009B 4931A20001R 6871A30008C 6871A20222C 6871A30008D 6871A20222D 3531ap2352k 3531AP2352J 3530A10011B 5230AP3116A 5230AP3116A 4A70152B 4A70152B 5983AP1156C 4980AP1154A 3041A20003B 3041A20003B 3551A30019B 3551A30019B 4975AP3778A 4975AP3778A 3660AP1221A 3661AP2582A 4681AP2544H 4681AP2544H 4681AP2949D 5834AP1097A 3086AP1217A 5251AR1222J 3H00611C 3087AP2581A 6871A20213C 6871A20213D 4995A10049J 4995A10049K 5420AP2577E Q'TY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2(4) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remark
5834AP1097A 5834AP1097A 5251AR1222J 3H00611C 2h00841J 3087AP2581B 6871A20067A 6871A20067B 4995A2084B 4995A2084A 5420AP2577E
47
2. Outdoor Unit
554031
437213-1
48
447910
C S R
349480 W6640
135301
3530A20007B 1A00202C 3A02284L 3Q35015G 6871A20015R 6920AP3400A 4948AP2527A 3041A30003K 3A01919B 3H03266H 2A01041K 1A00208D 2A01043A 4681A20008N 3A02027B 2A00392E 2A00393Q 6140AP2096Q 2A01032D COMPRESSOR PROPELLER 1A00195B SWITCH, PRESSURE 3A02524A 4995A20025R CONTROL BOX, ASSY, OUTDOOR PCB, SOFT START CAPACITOR 2A00986A CAPACITOR 2A00986D CAPACITOR TERMINAL BLOCK 3H00390B
Only Australia
49
Parts No. Location No. 430410 554031 554160 552203-1 552203-2 447910 546810 559010 437213-1 437212-1 437210 349480 135301 649950 W0CZZ-1 269201 W6640 W0CZZ-2 437213-2 435512 Parts Name BASE W. ASSY CONDENSER ASSY, BENT COMP VALVE SVC VALVE SVC BARRIER ASSY MOTOR, FAN PROPELLER FAN SIDE PANEL-L REAR GRILLE FRONT PANEL ORIFICE DISCHARGE GRILLE BOX ASSY, OUTDOOR SH-CAPACITOR RELAY TERMINAL BLOCK SH-CAPACITOR SIDE PANEL-R TOP COVER ASSY LP-K3023AA 2A00392F 2A00393A 2H02110A 1A00195B LPK3023CA/CL 2A00392F 2A00393A 2H02110A 1A00195B Q'TY Remark LPLPK3063CA/CL/CM K4023CA/CL/CM 2A02084A 2A01032D 2A00392F 2A00393A 2H02110A 1A00195B 6140AP2096E 2A01196A 2A00392F 2A00393A 2A01043A 2H02113R 1A00195A 1A00202C 1A00208D 2A01041C 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
4948AP2527A 4948AP2527A 4948AP2527A 4948AP2527A 3530A20007B 3530A20007B 3530A20007B 3530A20007B 4995A20025Q 4995A20025Q 2A00986A 4G00103A 1A00986D 3H03266J 2A00986A 4G00103A 1A00986D 3H03266J 2A00986A 4G00103A 3A01919B 3H03266J 6615AP2793H 2H00841J 2A00771D 4G00103C 1A00986S 3A02284F 3H03266H
50
P/No.: 3828A20156A