Room Air Conditioner

(Convertible Type)

SERVICE MANUAL
MODEL: LV-B2461CL/ B2461HL LV-B2464CL/ B2464HL LV-B1861CL/ B1861HL LV-B1864CL/ B1864HL

Contents
Functions .................................................................................................................................3 Product Specifications (Cooling Only)..................................................................................5 Product Specifications (Cooling & Heating).........................................................................6 Dimensions ..............................................................................................................................7 Refrigeration Cycle Diagram ..................................................................................................9 Wiring Diagram......................................................................................................................11 Operation Details ..................................................................................................................13 Display Function ...................................................................................................................21 Self-diagnosis Function........................................................................................................21 Installation .............................................................................................................................22 Operation ...............................................................................................................................39 Disassembly of the parts (Indoor Unit) ...............................................................................41 2-way, 3-way Valve.................................................................................................................45 Cycle Troubleshooting Guide...............................................................................................51 Electronic Parts Troubleshooting Guide.............................................................................52 Electronic control device......................................................................................................56 Schematic Diagram ...............................................................................................................57 Exploded View and Replacement Parts List.......................................................................58

Functions
Indoor Unit
Operation ON/OFF by Remote controller Sensing the Room Temperature Room temperature sensor. (Thermistor) Room temperature control Maintains the room temperature in accordance with the Setting Temp. Starting Current Control Indoor fan is delayed for 5 seconds at the starting. Time Delay Safety Control Restarting is inhibited for approx. 3 minutes. Indoor Fan Speed Control High, Med, Low, Chaos Operation indication Lamps (LED) --- Lights up in operation --- Lights up in Sleep Mode --- Lights up in Timer Mode --- Lights up in Deice Mode or Hot Start Mode (only Heating Model) --- Lights up during compressor running (only Cooling Model) Soft Dry Operation Mode Intermittent operation of fan at low speed. Sleep Mode Auto Control The fan is switched to low(Cooling), med(Heating) speed. The unit will be stopped after 1, 2, 3, 4, 5, 6, 7 hours. Natural Air Control by CHAOS Logic The fan is switched to intermittent or irregular operation The fan speed is automatically switched from high to low speed. Airflow Direction Control The louver can be set at the desired position or swing up and down, right and left (not on all models) automatically. Auto Operation The setting temperature, indoor fan speed and desired operation made are automatically set by fuzzy rule. 3

Deice (defrost) control (Heating) Both the indoor and outdoor fan stops during deicing. Hot start after deice ends. Hot-start Control (Heating) The indoor fan stops until the evaporator piping temperature will be reached at 28C(22C).

Remote Controller
Operation ON/OFF

Operation Mode Selection Cooling Operation Mode.(

(Cooling (Heating model only) model only)

) )

Auto Operation Mode.( Heating Operation Mode.(

) )

Soft Dry Operation Mode.(

Fan Speed Selection (Low) Room Temperature Display : High:39C LOW:11C Temperature Setting
TEMPERATURE LOW HIGH

(Med)

(High)

(CHAOS)

Cooling

Down to 18C Up to 30C,

Heating

Down to 16C Up to 30C,

Setting the Time or Timer

Timer Selection
ON OFF

: OFF, ON, OFF ON

Timer Setting
SET

Timer Cancel
CANCEL

: Cancel Sleep Mode, Timer ON or Timer OFF.

Sleep Operation : 1, 2, 3, 4, 5, 6, 7hr, Off Timer Airflow Direction Control

Fan Operation Mode : Fan Operates without cooling. (Cooling model only) Reset

Product Specifications (Cooling Only)

Model Name LV-B1861CL Item Cooling Capacity Moisture Removal Power Source Air Circulation Input Running Current E.E.R. Dimensions (WHD) Net. Weight Refrigerant (R-22) Airflow Direction Control (Up & Down) Remocon Type Service Valve & Connecting Tube Sleeping Operation Drain Hose Connecting Wire Main Power Cable 1.5mm2 (2.0mm2:for the Middle East) Time Delay Safety Function Air Circulation Soft Dry Fan Speed (Indoor) Timer Self-Diagnosis Auto-Restart O O O 3 (Hi, Med, Low) 24Hrs O O Liquid Gas 1/4" (6.35) 1/2" (12.7) O O 0.75mm
2

LV-B1864CL

LV-B2461CL 24,000(6,048) 3.5

LV-B2464CL 24,000(6,048) 3.5

Unit Btu/h(kcal/h) /h , V, Hz Indoor Outdoor W A Btu/h-W Indoor Outdoor Indoor Outdoor g 880 O L.C.D Wireless 1/4" (6.35) 5/8" (15.88) O O 1/4" (6.35) 5/8" (15.88) O O kg 57 1,050 mm 1,935 9.0 9.3 m3/min 14.0 50 1,850 9.2 9.7 18,000(4,536) 2.5

1, 220-240V, 50Hz 16.0 50 2,500 11.9 9.6 16.0 50 2,500 11.9 9.6

1,200 x 205 x 615 870 x 655 x 320 30 57 1,550 O 57 1,550 O

2.5mm2

2.5mm2

Product Specifications (Cooling & Heating)

Model Name LV-B1861HL Item Cooling Capacity Heating Capacity Moisture Removal Power Source Air Circulation Input Indoor Outdoor Cooling Heating Running Current Cooling Heating E.E.R.(Cooling) C.O.P.(Heating) Dimensions (WHD) Net. Weight Refrigerant (R-22) Airflow Direction Control (Up & Down) Remocon Type Service Valve & Connecting Tube Sleeping Operation Drain Hose Connecting Wire Main Power Cable 1.5mm2 (2.0mm2:for the Middle East) Time Delay Safety Function Air Circulation Soft Dry Fan Speed (Indoor) Timer Self-Diagnosis Auto-Restart 6 O O O 3 (Hi, Med, Low) 24Hrs O O Liquid Gas 1/4" (6.35) 1/2" (12.7) O O 0.75mm2 2.5mm2 Indoor Outdoor Indoor Outdoor g 1,310 O L.C.D Wireless 1/4" (6.35) 5/8"(15.88) O O kg 58 1,280 Btu/h-W w/w mm A W 1,950 1,860 8.9 8.5 9.74 3.15 1,200 x 205 x 615 870 x 655 x 320 30 58 1,390 O Unit Btu/h(kcal/h) Btu/h(kcal/h) /h , V, Hz m3/min 14.5 45 1,850 1,850 9.2 9.2 19,000(4,788) 20,000(5,040) 2.5 1, 220-240V~, 50Hz 16 50 2,670 2,570 12.3 11.9 8.98 2.73 24,000(6,048) 24,000(6,048) 3.5 LV-B1864HL LV-B2461HL LV-B2464HL

Dimensions
(1) Indoor Unit
1200mm

61

5m

205mm
63mm 38mm

26

5m

39 m

2m

46

8m

175mm

(Installation Plate)
250mm

36

mm

7 10

6m

(Rear Side)
36 mm

(2) Outdoor Unit

W

L3

L4

L2

L1

L10 L11

Gas side 3-way valve Liquid side 3-way valve

L5

L7

L6

L8

L9

MODEL DIM W H D L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 mm mm mm mm mm mm mm mm mm mm mm mm mm mm

LV-B1861CL/HL, LV-B1864CL/HL, LV-B2461CL/HL, LV-B2464HL, LV-B2464CL 870 655 320 370 25 340 630 25 546 162 162 54 74.5 79 8

Refrigeration Cycle Diagram

LV-B1861CL LV-B1864CL LV-B2461CL LV-B2464CL INDOOR UNIT
LIQUID SIDE

OUTDOOR UNIT
CAPILLARY TUBE

HEAT EXCHANGER (EVAPORATOR)

HEAT EXCHANGER (CONDENSER)

GAS SIDE

COMPRESSOR

Pipe size(Diameter: ) MODEL Gas LV-B1861CL LV-B1864CL LV-B2461CL LV-B2464CL 1/2" 1/2" 5/8" 5/8" Liquid 1/4" 1/4" 1/4" 1/4"

Piping length(m) Rated 5 5 5 5 Max 15 15 20 20

Elevation(m) Rated 5 5 5 5 Max 8 8 8 8

For installation over rated distance, 30g of refrigerant should be added for each meter. ex) When installed at a distance of 15m, 300g of refrigerant should be added. (15-5) x 30g = 300g

 LV-B1861HL LV-B1864HL LV-B2461HL LV-B2464HL INDOOR UNIT

LIQUID SIDE

OUTDOOR UNIT
CAPILLARY TUBE CHECK VALVE

CAPILLARY TUBE HEAT EXCHANGER HEAT EXCHANGER

GAS SIDE REVERSING VALVE COOLING HEATING

COMPRESSOR

Pipe size(Diameter: ) MODEL Gas LV-B1861HL LV-B1864HL LV-B2461HL LV-B2464HL 1/2" 1/2" 5/8" 5/8" Liquid 1/4" 1/4" 1/4" 1/4"

Piping length(m) Rated 5 5 5 5 Max 15 15 20 20

Elevation(m) Rated 5 5 5 5 Max 8 8 8 8

For installation over rated distance, 30g of refrigerant should be added for each meter. ex) When installed at a distance of 15m, 300g of refrigerant should be added. (15-5) x 30g = 300g

10

Wiring Diagram
(1) Indoor Unit
1. LV-B1861CL/1864CL/2461CL/2464CL
CAPACITOR BR YL OR RD BL BK TRANSFORMER CN-TRANS CN-FAN RY-L RY-M RY-H THERMISTOR CAPACITOR CN-TH BR YL OR RD BL BK

2. LV-B1861HL/2461HL
TRANSFORMER CN-TRANS CN-FAN RY-L RY-M RY-H THERMISTOR

CN-TH

GN/YL

MOTOR

MAIN PCB ASSY.

GN/YL

MOTOR

MAIN PCB ASSY.

DOOR S/W 1,2

DOOR S/W 1,2

CN-UP/DOWN 1,2

GN/YL
3 FUSE T3.15A

STEP MOTOR

GN/YL BR WH
3 FUSE T3.15A

CN-UP/DOWN 1,2 CN-DISP

STEP MOTOR

RY-COMP CN-4WAY

STEP MOTOR

BL BK

RY-COMP CN-4WAY RY RD

STEP MOTOR

BL GN/YL WH BR BL CN-DISP

BL

1(L) 2(N)

TERMINAL BLOCK

GN/YL

DISPLAY PCB ASSY.

1(L) 2(N)

TERMINAL DISPLAY PCB BLOCK ASSY.

TO OUTDOOR UNIT
POWER INPUT

POWER INPUT

TO OUTDOOR UNIT

CONVERTIBLE(COOLING ONLY)

(INDOOR)

CONVERTIBLE(HEAT PUMP)

(INDOOR)

(2) Outdoor Unit

3. LV-B1864HL/2464HL
CAPACITOR BR YL OR RD BL BK TRANSFORMER CN-TRANS CN-FAN RY-L RY-M RY-H THERMISTOR

1. LV-B1861CL/1864CL/2461CL/2464CL
YL
R

CN-TH

BL

BR(OR)

GN/YL

MOTOR

MAIN PCB ASSY.

COMP.
S

GN/YL FAN MOTOR

DOOR S/W 1,2

GN/YL BR WH BL BK BL RD RT-OUTFAN GN/YL

3 FUSE T3.15A

CN-UP/DOWN 1,2

STEP MOTOR

RD

RY-COMP CN-4WAY RY-4WAY

STEP MOTOR

H C

CAPACITOR
CN-DISP

BR

T/B BL BR

BK

1(L) 2(N)

TERMINAL DISPLAY PCB BLOCK ASSY.

3
POWER INPUT

TERMINAL BLOCK

TO OUTDOOR UNIT

CONVERTIBLE(HEAT PUMP)

(INDOOR)

TO INDOOR UNIT CONVERTIBLE(COOLING ONLY)

(OUTDOOR)

11

2. LV-B2461HL
BL
R

3. LV-B1861HL
CAPACITOR CAPACITOR BL
R

CAPACITOR

CAPACITOR

BK

HIGH PRESSURE S/W(FOR HEATING)

REVERSING COIL

FAN MOTOR

BR(OR)
THERMISTOR

REVERSING VALVE

FAN MOTOR

BR(OR)
THERMISTOR

GN/YL BK BK

GN/YL

BK

BK

BR

BR

T/B

L3 L2 L1

L3 L2 L1

WH

WH

BK

BK

YL BK
GN/YL

BK

BK

YL BK
GN/YL

7
GN/YL

TO INDOOR UNIT CONVERTIBLE(HEAT PUMP) (OUTDOOR)

TO INDOOR UNIT CONVERTIBLE(HEAT PUMP) (OUTDOOR)

4. LV-B1864HL/2464HL
BL
R

5. LV-B2464HL(Australia only)
YL YL

CAPACITOR
H C F

COMP. S
C

RD

YL FAN OR(BR) MOTOR BK

R COMP. S C RD

START CAPACITOR CAPACITOR YL H C F OR(BR) FAN MOTOR BL BK

GN/YL

REVERSING VALVE

GN/YL
T/B

REVERSING VALVE

GN/YL

TERMINAL BLOCK

TERMINAL BLOCK

BK

BK

BK T/B

BK BK BR

BK 3 4
CN-COMP

BL

BL BK BK BR
GN/YL

3 4
CNS/CAPA

BR

BL

BK

BK
GN/YL

CN-POWER

SOFT START PCB TERMINAL BLOCK

7
GN/YL

TERMINAL BLOCK

TO INDOOR UNIT CONVERTIBLE(HEAT PUMP)

TO INDOOR UNIT

(OUTDOOR)

WIRING DIAGRAM(OUTDOOR)

3854A20075W

12

HIGH PRESSURE S/W(FOR HEATING)

YL

YL

BK

BL

BL

BK

BK

BK
W H

BK

COMP. S

RD

COMP. S

RD

Operation Details
(1) The function of main control
1. Time Delay Safety Control
3min The compressor is ceased for 3minutes to balance the pressure in the refrigeration cycle. (Protection of compressor) Vertical air flow direction control louvers open in 5 seconds to prevent noise between louvers and wind. 5sec 30sec The 4-way valve is ceased for 30sec. to prevent the refrigerant-gas abnormal noise when the Heating operation is OFF or switched to the other operation mode while compress is off. While compressor is running, it takes 3~5 seconds to switch.

2. Airflow Direction Control

This function is to swing the louver up and down automatically and to set it at the desired position. The procedure is as the following. 1st ; Press the ON/OFF Button to operate the product. 2nd ; Press the Airflow Direction Control Button to swing the louver up and down automatically. 3nd ; Repress the Airflow Direction Control Button to set the louver as the desired position.
MODE 0 MODE1 MODE 2 MODE 3 MODE 4 MODE 5 MODE 6 MODE 7 MODE 9 (CLOSE) 135 Cooling

For Heating Model

Airflow direction control figure when installed on the floor.
OPEN MODE 1 MODE 2 MODE 3 MODE 4 MODE 5 MODE 6 MODE 7 MODE 8 MODE 9 CLOSE Heating Heating 135 Cooling 12

Airflow direction control figure when installed under the ceiling.

OPEN MODE 1 MODE 2 MODE 3 MODE 4 MODE 5 MODE 6 MODE 7 MODE 8 MODE 9 CLOSE Cooling Heating 135 12

OPEN MODE 1 MODE 2 MODE 3 MODE 4 MODE 5 MODE 6 MODE 7 MODE 8 MODE 9 CLOSE Heating Heating 135 Cooling 12

13

3. Cooling Mode Operation

When selecting the Cooling( ) Mode Operation, the unit will operate according to the setting by the remote controller and the operation diagram is as following Intake Air temp. COMP. ON (SET TEMP.+0.5C) COMP. OFF (SET TEMP. -0.5C)

More than 3 minutes

More than 3 minutes Selecting fan speed ON Low OFF Selecting fan speed ON

INDOOR FAN COMPRESSOR

Selecting fan speed ON

Low OFF

4. Cooling or Heating Mode with Sleep Mode Auto Operation

When selecting the Cooling( ) or the Heating( ) combined with the Sleep Mode Auto Operation( operation diagram is as following. Cooling Mode with the Sleep Mode The setting temperature will be raised by 1C 30minutes later and by 2C 1 hour later. The operation will be stopped after 1, 2, 3, 4, 5, 6, 7 hours. Intake Air temp. COMP. ON (SET TEMP.+0.5C) COMP. OFF (SET TEMP. -0.5C) INDOOR FAN COMPRESSOR Low ON More than 3 minutes Low OFF Low ON 30 minutes 30 minutes
1C 1C

), the

More than 3 minutes Low OFF Low ON

Heating Mode with the Sleep Mode. The operation will be stopped after 1, 2, 3, 4, 5, 6, 7 hours.

Setting Temp. +3C (Compressor OFF) Setting Temp. (Compressor ON) Indoor Fan Compressor Low. ON Low. OFF Low. ON Low. OFF Low. ON Low. OFF

14

5. Auto Operation
The operation procedure is as following. (Cooling & Heating Model) Press Start/Stop Button

Select Auto Operation Mode

Check the Room temperature

Operation mode Indoor fan speed Setting temperature Intake-air temperature Operation Mode

are automatically decided by Fuzzy rule.

below 21C Heating

Over 21C

below 24C

Over 24C Cooling

Soft Dry

* If initial mode is decided, that mode is continued without the room temperature changing. * For cooling operation mode over 24C setting temperature and fan speed are same as cooling only model. Auto Operation for Cooling. (Cooling only Model) Operation Condition Intake-air Temperature Over 26C When Auto Operation initial start Over 24C~below 26C Over 22C~below 24C Setting temperature 25C Intake air -1C Intake air -0.5C Controlled by Fuzzy logic In this mode, when pressing the vertical air diretion control. Button, louvers moves to 1/f rhythm (refer to page 17) Fan speed Air Direction Control

Over 20C~below 22C intake air temperture below 20C When pressing room temp- Over 20C~below 30C erature setting button below 20C during Auto Operation over 30C Intake-Air temp Setting Temp. +0.5C (Compressor OFF) Setting Temp.-0.5C (Compressor ON) 20C Fuzzy control 20C 30C

Indoor Fan Compressor ON OFF 15

Fuzzy Speed ON OFF

 Auto Operation for Soft Dry The Setting temperature will be same as that of the current intake-air temperature. - Compressor ON temperature; Setting temperature +1C - Compressor OFF temperature; Setting temperature -0.5C

Auto Operation for Heating. Intake Air temp. Setting temp. below 20C 20C over 20~below 21C Intake air temp. +0.5C

- Compressor ON temperature; Setting temperature - Compressor OFF temperature; Setting temperature +3C

Setting temp. 21.5C

20.5C

20C

20C

21C

Intake-Air temp.

1/f rhythm louver operation : In Auto operation mode, when pressing the vertical air direction control button, louver moves as following cycle. MODE0 MODE1 MODE2 MODE3 MODE4 MODE5 MODE6 End MODE9 (CLOSED) 16 Start

6. Natural wind by CHAOS logic

For more fresh feeling than other fan speed mode, press the indoor fan Speed Selector and set to CHAOS mode. In this mode, the wind blows like natural breeze by automatically changing fan speed according to the CHAOS logic.

Intake Air temp.

Setting CHAOS Natural wind

Cooling on temp. (Setting temp.+0.5) Setting temp. Cooling off temp. (Setting temp.-0.5)

INDOOR FAN OUTDOOR FAN/COMP. : Setting fan speed : CHAOS Natural wind : LOW : COMP ON : COMP OFF

GRAPH of Natural wind by the CHAOS logis (During Cooling operation)

Intake Air temp.

Setting CHAOS Natural wind

Heating off temp. (Setting temp.+3.0)

Heating on temp. (Setting temp.)

30sec

INDOOR FAN OUTDOOR FAN/COMP. : Setting fan speed : CHAOS Natural wind

LOW OR STOP

: LOW

: COMP ON

: COMP OFF

GRAPH of Natural wind by the CHAOS logis (During Heating operation)

17

7. Heating Mode Operation

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

For Heating Model

Indoor piping temp.

28C 26C

Intake Air temp. Setting temp. +3.0C (Compressor OFF) Setting temp. (Compressor ON)
minimum 1min.
COMPRESSOR OUTDOOR FAN INDOOR FAN 4-WAY VALVE
Fan Stops ON ON Low Fan Selected Fan

minimum 3min.
OFF OFF Low Fan ON ON Selected Fan ON

minimum 30sec. minimum 3min.

OFF OFF Low Fan Fan Stop

minimum 1min.
ON ON Low Fan Selected Fan

8. Hot-Start Control
The indoor fan stops until the evaporator piping temperature will be reached to 28. During heating operation, if piping temperatures falls below 26C fan stops. The operation diagram is as following.

PIPING TEMPERATURE
28C (22C) 26C (20C)

1min

INDOOR FAN COMPRESSOR : Selected Fan : Low Fan ON : Fan Stop

18

9. Deice Control
Deicing operation is controlled by timer and sensing the outdoor piping temperature. The first deicing starts only when the outdoor pipe temperature falls below -6C after 45(30) minutes passed from starting of heating operation. Deicing ends after 10(6) minutes passed from starting of deice operation or when the outdoor pipe temperature rises over 12C even if before 10(6) minutes. The second deicing starts only when the outdoor pipe temperture falls below -6C after 45(30) minutes passed from ending of the first deicing.
The outdoor piping Temp. 12C DEICE OFF More than 45(30) minutes of heating operation Within More than 45(30) minutes 10(6) minutes of heating operation Deicing

Deicing

-6C DEICE ON HOTSTART

INDOOR FAN COMPRESSOR 4-WAY VALVE

ON ON ON OFF

OFF ON ON

ON ON

OFF ON OFF

10. Soft Dry Operation

During Soft Dry Operation, the compressor ON temperature is the setting temperature plus 1C, the compressor OFF temperature is the setting temperature minus 0.5C. When the room temperature rises over the compressor ON temperature, the operation mode is switched to the cooling mode. When the room temperature falls between the compressor ON temperature and OFF temperature, the operation mode is switched to the Soft Dry Operation. In this temperature range, 10min. Dry Operation, 7min operation OFF. During 10min Dry operation, if the room temperature falls below compressor OFF temperature, Compressor OFF. In micom dehumidify mode, control of fan speed is as following.
Intake Air temp.

Setting temp. +1.0C (Compressor ON) Setting temp. Setting temp. -0.5C (Compressor OFF)
Cooling 2min.58sec. 10min.
COMPRESSOR OUTDOOR FAN INDOOR FAN ON ON
Selected Fan

7min.
OFF OFF
Low Fan

10min. Within 7min. Cooling 2min.58sec.

ON ON OFF OFF ON ON
Selected Fan

OFF OFF

ON ON

OFF OFF

ON ON
Low Fan

OFF OFF

19

11. Forced operation

If you lose wireless remote controller, you can operate the unit with forced operation switch. The standard conditions are as following. Cooling Model Room Temp 24C Operation Mode FAN Speed Setting Temp. Cooling High 24C Cooling High 22C Heat pump Model 21CRoom Temp24C Soft Dry Soft Dry Rule Air Intake Temperature Room Temp21C Heating High 24C

Unit operates in low fan mode for first 15 seconds, then switched to proper operation mode according to intake Air temperature. Forced Operation Button
R

Press the Forced Operation Button.

Press the Forced Operation Button once again to stop operation.

12. Protection of the evaporator pipe from frosting

If the temperature of the indoor coil is below 0C after 7 minutes from starting the compressor, the

compressor and the outdoor fan is stopped, and then after 3 minute delay of the compressor and the temperature of the indoor coil is over 7C, the compressor and the outdoor fan is reoperated. Indoor fan operates at low speed (comp. OFF) or at selected speed (comp. ON)

13. Inlet grille open

Once the inlet grille is opened during operation of the unit, the unit automatically stops operation and the lamps will be turned-off. But memorized functions are still available. When the inlet grille is closed again, the unit become waiting state for operation. From then, the unit can be operated by forced operation button or Start/Stop button of remote controller.

14. Test Operation

When pressing forced operation switch about 3 seconds, the unit operates in cooling mode at high speed fan regardless of room temperature and resets in 18 min. During test operation, if remote controller signal is received, the unit operates as remote controller sets.

15. Auto Restarting Operation

When the power is restored after a sudden power failure while in appliance operation, the mode before the power failure is kept on the memory and the appliance should be on the automatically operates in the mode on the memory. Operation Mode that is kept on the memory - State of Operation ON/OFF - Operation Mode/Setting Temp/Selected airflow Speed - Sleep Timer Mode/Remaining Time of Sleep Timer(unit of hour)

20

Display Function
1. Heating Model
Operation Indicator Coolling, Soft Dry, Fan, Heating Timer Indicator Timer Mode Sleep Timer Indicator Sleep Mode Deice Indicator Hot-start, Deice

2. Cooling Model
Operation Indicator Coolling, Soft Dry, Fan, Heating Timer Indicator Timer Mode Sleep Timer Indicator Sleep Mode Outdoor Unit Operation Outdoor Unit Operating

Note) For normal operation after checking by test mode, you should press SW1 nine times for resetting or reconnect the power cord.

Self-diagnosis Function
1. Protection of the evaporator pipe from frosting
If the temperature of the indoor pipe is below 0C after 7 mins from starting the compressor, the compressor and the outdoor fan is stopped, and then after 3 mins delay of the compressor and the temperature of the indoor pipe is over 7C, the compressor and the outdoor fan is reoperated.

2. Thermistor Cut Off or Short

Cut Off/Short : Blinks on and off the operation mode LED. (0.5 sec ON/3 sec OFF)

21

Installation
1. Installation of Indoor, Outdoor Unit 1. Selection of the best location
1) Indoor unit
There should not be any heat source or steam near the unit. There should not be any obstacles to prevent the air circulation. A place where air circulation in the room will be good. A place where drainage can be easily obtained. A place where noise prevention is taken into consideration. Do not install the unit near the door way. Ensure the spaces indicated by arrows from the wall, ceiling, or other obstacles.
More than 20cm
R

More than 20cm

More than eye-level

(Ceiling installation)
More than 20cm

More than 20cm

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 hot air discharged. Ensure the spaces indicated by arrows from the wall, ceiling, fence or other obstacles.

(Floor/Wall installation)

More than 10cm

More than 10cm

More than 70cm

3) Piping length and the elevation

Pipe Size MODEL 18K BTU 24K BTU GAS 1/2" 50Hz 5/8" 60Hz 5/8" LIQUID 1/4" 1/4" 3/8" 7 20 Length A(m) Rated 7 Max. 15 Elevation B(m) Rated 5 5 Max. 8 8 * Additional refrigerant (g/m) 30 30 B Outdoor unit

Indoor unit

If 18K or 24K Model is installed at a distance of 15m, 240g of refrigerant should be added ........................................................(15-7)x30g

22

2. Indoor unit installation

s Before Installing, prepare Installation Plates 'Installation Plates' are attached at the bottom of indoor unit. Detach them by removing each 3 screws at both sides. Detach 'Side Plate (R,L)' by removing each 2 screws on both sides. Pull the upper right and left side of 'Inlet Grille' to the front, and it will stop at slightly tilted position. Unhook the 'Inlet hanger' from the 'Hanger screw' on the both left and right side. Detach the 'Inlet Grille' from the Indoor Unit.
Side Plate
R

Install Plate

1) Installation on the ceiling

Measure and mark the position for the Suspension bolts and the piping hole. Drill the hole for anchor nut on the ceiling.
Inlet Grille
R

Inlet hanger

Hanger screw 1076 265

1)

Before secure the Installation Plates, select the bent direction of the Installion Plate to the inside or the outside according to the installation circumstances.

Suspension bolt

Center-line for the piping hole 265

2)

1236

Drill the piping hole on the wall slightly tilted to the outdoor side using a 70 hole-core drill.

Indoor

WALL

Outdoor 5~7mm

23

 Insert the nuts and washer onto the suspension bolts for locking the suspension bolts on the ceiling. Mount the suspension bolts to the anchor-nuts firmly. Secure the Installation plates onto the Suspension bolts (adjust level roughly.) using nuts, washers and spring washers.

1)
Nut

Anchor nut Ceiling

Washer

Suspension bolts

Suspension bolts Spring washer Nut

max. 12mm

Washer

2)

Engage 2 hooks on the both left and right side of the unit to the lower slot of Installation Plates. Adjust a level with a level gauge on the direction of left-right, back-forth by adjusting suspension bolts. Move the hooks on the unit to the upper slot of Installation Plates. Then the unit will be declined to the bottomside so as to drain well.

Lower slot Level gauge

Suspension bolt

Adjust a level

Installation plate

Upper slot

24

CAUTION

1. Install declination of the indoor unit is very important for the drain of the convertible type air conditioner. 2. Minimum thickness of the insulation for the connecting pipe shall be 7mm. 3. If the Installation Plates are fixed to horizontal line, the indoor unit after installing will be declined to the bottomside.

Front of view
The unit must be horizontal or declined to the drain hose connected when finished installation.
Ceiling

Drain hose

Ceiling

Side of view
The unit must be declined to the bottomside of the unit when finished installation.
Ceiling

25

 Secure the unit to the Installation Plates with four M8 bolts and washers.

Before working, refer to "Connecting pipe and cable to Indoor Unit" on page 32.
Hook up the Inlet Grille Hook to the cabinet. Hang the Inlet Hanger to the screw.
Inlet hanger

Hook Cabinet Bottom

Fit the projection hooks of the side plates to the 'Side Panel' and the 'Front Panel' by lifting it. Fasten the screws.
2

26

2) Installation on the Wall

Select and mark the position for fixing bolts and piping hole. Decide the position for fixing bolts slightly tilted to the drain direction after considering the direction of drain hose. Drill the hole for anchor nut on the wall.
1076 mor e th 260 an

265

Drill the piping hole on the wall slightly tilted to the outdoor side using a 70 hole-core drill.
Indoor

Wall Outdoor

Secure the 'Install Plate' onto the wall with four anchor bolts, washers and spring washers.
Spring washer

Wall

Nut

Washer Anchor nut

Less than 12mm

Before secure the Install Plates, select the bent direction of the 'Install Plate' to the inside or outside according to the installation circumstances.

123

27

5~7mm

Install the Indoor unit onto Installation Plate. Insert 2 hooks on the both left and right side of the unit to the inner slot (wall side) of the Installation Plate. Secure the unit to the Installation Plate with four M8 bolts and washers.
R

Inner slot

Before working, refer to "Connecting pipe and cable to Indoor Unit" on page 32.
Hook up the Inlet Grille Hook to the cabinet. Hang the Inlet Hanger to the screw.

Fit the projection hooks of the side plates to the 'Side Panel' and the 'Front Panel' by lifting it. Fasten the screws.

28

3) Installation on the floor

Installation of Mount Bracket. Select and mark the position for Mount Brackets and the piping hole. Drill the hole for the anchor nut on the wall. Drill the piping hole using a 70 hole-core drill. Secure the Mount Brackets on the wall with four M4 screws. Install the indoor unit onto the Mount Brackets. Engage the slot at the back of the unit with Mount Bracket.
From the left wall more than 760mm From the right wall more than 840mm

Slot Floor mount bracket

448mm

Drill the piping hole with 70mm dia, hole core drill. Piping hole should be slightly slant to the outdoor side.

Wall Indoor Outdoor

After Installing, reassemble detached parts. Hang the 'Inlet Grille' and hook the 'Inlet Hanger' to the Hanger Screw. Assemble the 'Side Plates(R,L)' with 2 screws on both left and right side.

Slot Wall

Floor mount bracket Install plate Piping hole

29

5~7mm

3. Connecting Pipes to the Indoor Unit 3-1. Preparation of Piping

Main cause of gas leakage is defect in flaring work. Carry out correct flaring work in the following procedure. 1) Cut the pipes and the cable. s Use the accessory piping kit or the pipes purchased locally. s Measure the distance between the indoor and the outdoor unit. s Cut the pipes a little longer than measured distance. s Cut the cable 1.5m longer than the pipe length. 2) Burrs removal s Completely remove all burrs from the cut cross section of pipe/tube. s Put the end of the copper tube/pipe to downward direction as you remove burrs in order to avoid to let burrs drop in the tubing. 3) Putting nut on s Remove flare nuts attached to indoor and outdoor units, than put them on pipe/tube having completed burr removal. (Not possibe to put them on after flaring work) 4) Flaring work s Carry out flaring work using flaring tool as shown below. Outside diameter mm 12.7 15.88 inch 1/2 5/8 A mm 0 ~ 0.5 0 ~ 1.0
Copper pipe Clamp handle Red arrow mark Copper tube 90 Slanted Uneven Rough

Pipe Reamer

Point down

Flare nut

Copper tube

Handle Bar Bar "A" Yoke Cone

Firmly hold copper tube in a die as indicated dimension in the table above.

Smooth all round Inside is shining without scratches

= Improper flaring =

5) Check s Compare the flared work with figure below. s If flare is noted to be defective, cut off the flared section and do flaring work again.

Even length all round

Inclined Surface Cracked Uneven damaged thickness

30

3-2. Installation on the ceiling

1) Connecting the pipes to the indoor unit
The pipe can be connected to right side, bottom or back of the unit. 1. For the Right Side Piping After bending an end of the connecting tube, align the center of the pipings and sufficiently tighten the flare nut with fingers. Finally, tighten the flare nut with torque wrench until the wrench clicks. Connect the Drain Hose insulated to the drain outlet. Drain hose should be go through under the Hose Bracket as shown in figure . Hang the drain hose on the hose hanger and fix it to the hole of the hose bracket with a screw.
R

Hose Bracket 3

4 Piping 5

Drain Hose Hose Hanger

2. For the Bottom Side Piping Remove the knock-out on the bottomside of Inlet Grille Align the center of the pipings and sufficiently tighten the flare nut with fingers. Finally, tighten the flare nut with torque wrench until the wrench clicks. Connect the Drain Hose insulated to the drain outlet. Hang the drain hose on the hose hanger and fix it to the hole of cabinet bottom with a screw.

Hose Hanger

2) Connecting the Drain Hose

The drain hose can be connected to not only the right side but also left side of the unit. If the drain hose is connected to the left side, it should go through the cabinet bottom. Hang the drain hose on the hose hanger and fix it to the hole of cabinet bottom with a screw.

BOTTOM Hose Hanger Drain Hose

31

3-3. Installation on the wall or floor

1) Connecting the pipes to the indoor unit
1. For the Right Rear Piping Remove the knock-out at the back side of the cabinet. After bending an end of the connecting tube, align the center of the pipings and sufficiently tighten the flare nut with fingers. Finally, tighten the flare nut with torque wrench until the wrench clicks. Connect the Drain Hose insulated to the drain outlet. Tape the Drain Hose to the pipings to avoid coming off the drain-outlet. 2. For the Right Side Piping After bending an end of the connecting tube, align the center of the pipings and sufficiently tighten the flare nut with fingers. Finally, tighten the flare nut with torque wrench until the wrench clicks. Connect the Drain Hose insulated to the drain outlet. Tape the Drain Hose to the pipings to avoid coming off the drain-outlet.
Piping Taping Drain Hose

Piping

Taping Drain Hose

3. For the Right Bottom Piping Align the center of the pipings and sufficiently tighten the flare nut with fingers. Finally, tighten the flare nut with torque wrench until the wrench clicks. Connect the Drain Hose insulated to the drain outlet.

Piping

Taping Drain Hose Connecting Cable

2) Connecting the Drain Hose

The drain hose can be connected to not only right side but also left side of the unit.

REAR

Drain Hose

BOTTOM

32

4. Connecting Pipes to the Outdoor Unit

1) Connecting the pipes to the Outdoor unit
1. Align the center of the pipings and sufficiently tighten the flare nut with fingers. 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.

Outdoor unit

Pipe Size Liquid Side Gas Side 1/4" 3/8" 1/2" 5/8"

Torque 1.8kgm 4.2kgm 5.5kgm 6.6kgm

Gas side piping (Bigger Dia.) Liquid side piping (Smaller Dia.) Torque wrench

5. Checking the Drainage

1) Checking the Drainage
1. Remove the Air Filter. To remove air filter, take hold of tab and pull slightly upwards.

2. Check the drainage. Spray one or two glasses of water upon the evaporator. Ensure that water flows drain hose of indoor unit without any leakage.
R

33

6. Connecting Cables between Indoor Unit and Outdoor Unit

1) Connecting cables to the Indoor Unit
1) Remove the Air guide - L by loosening 2 screws after removing the Inlet grille from the Indoor unit. 2) Connect the wires to the terminals on the control board individually according to the outdoor unit connection. Ensure that the color of the wires of outdoor unit and the terminal No. are the same as those of indoor unit respectively
R

AIR GUIDE-L

INDOOR UNIT

Clamp

1 2

Control Panel

2) Clamping of cables
1) Arrange 2 power cables on the control panel. 2) First, fasten the steel clamp with a screw to the inner boss of control panel. 3) For the cooling model, fix the other side of the clamp with a screw strongly. For the heat pump model, put the 0.75mm2 cable(thinner cable) on the clamp and tighten it with a plastic clamp to the other boss of the control panel. 4) In Australia, the length of power supply cord measured from the entry of the power supply cord to the middle of live pin on the power plug should be over 1.8m.

The power cord connected to the indoor unit should be complied with the following specifications (Type H05VV-F(Indoor) approved by HAR or SAA).
8.0mm 10.0mm

CAUTION The power connecting cable connected between the indoor and outdoor unit should be complied with the following specifications (Type H07RN-F approved by HAR or SAA).
8.0mm 10.0mm

The connecting cable connected between the indoor and outdoor unit should be complied with the following specifications (Type H07RN-F approved by HAR or SAA).
6mm

NORMAL CROSSSECTIONAL AREA 2.5mm2(24K) 2.0mm2(18K:for the Middle East) 1.5mm2(18K:for the other area)

NORMAL CROSSSECTIONAL AREA 2.5mm2(24K) 2.0mm2(18K:for the Middle East) 1.5mm2(18K:for the other area)

NORMAL CROSSSECTIONAL AREA 0.75mm2

34

3) Connecting the cable to Outdoor Unit

1. Remove the Cover control from the unit by loosening a screw. Connect the wires to the terminals on the control board individually as following. 2. Secure the cable onto the control board with the holder (clamper). 3. Refix the cover control to the original position with the screw. 4. Use a recongnized circuit breaker 20A(18K, 24K) between the power source and the unit. A disconnection device to adequately disconnect all supply lines must be fitted.

Outdoor unit
Terminal block Over 5mm Holder for power supply cord

Power supply cord Connecting cable

Cover control

Holder for connecting cable

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. 10) 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.

35

4) Form the pipings

1. Wrap the connecting portion of indoor unit with the Insulation material and secure it with two Plastic Bands. (for the right pipings) If you want to connect an additional drain hose, the end of the drain-outlet should keep distance from the ground. (Do not dip it into water, and fix it on the wall to avoid swinging in the wind.) In case of the Outdoor unit being installed below position of the Indoor unit.
Plastic Band Seal a small opening around the pipings with gum type sealer.

Taping Drain hose

Pipings Connecting cable Power supply cord

2. Tape the Pipings, drain hose and Connecting Cable from bottom to top. 3. Form the pipings gathered by taping along the exterior wall and fix it onto the wall by saddle or equivalent.

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

In case of the Outdoor Unit being installed above position of the Indoor Unit. 2. Tape the Pipings and Connecting cable from bottom to top. 3. Form the pipings gathered by taping along the exterior wall, and make the trap prevent water from entering into the room. 4. Fix the pipings onto the wall by saddle or equivalent.

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

Trap

36

7. Air Purging of the Pipes and Indoor Unit

The air which contains moisture remaining in the refrigeration cycle may cause a malfunction on the compressor. 1. Confirm that both the liquid side valve and the gas side valve are set to the closed position. 2. After connecting the piping, check the joints for gas leakage with gas leak detector. 3. Remove the service port nut, and connect the gauge manifold and the vacuum pump to the service port by the charge hose. 4. Vacuum the indoor unit and the connecting pipes until the pressure in them lowers to below -76cmHg. 5. Remove the valve stem nuts, and fully open the stems of the 2-way and 3-way valves with a hexagon wrench. 6. Tighten the valve stem nuts of the 2-way valve and 3-way valve. 7. Disconnect the charge hose and fit the nut to the service port. (Tightening torque: 1.8kg.m)

Indoor unit

Liquid side Closed 2-way valve/ 3-way valve

Outdoor unit

Gas side

3-way valve

Closed

Vaccum pump

OPEN

CLOSE

37

8. Test running
1) Connection of power supply
1. Connect the power supply cord to the independent power supply. Circuit breaker is required. 2. Prepare the remote control. Insert two batteries provided. Remove the battery cover from the remote controller. Slide the cover according to the arrow direction. Insert the two batteries. (Two "R03" or "AAA" dry-cell batteries or equivalent.) Be sure that the (+) and (-) directions are correct. Be sure that both batteries are new. Re-attach the cover. Slide it back into position. 3. Operate the unit for fifteen minutes or more.

2) Evaluation of the performance

1. Measure the temperature of the intake and discharge air. 2. Ensure the difference between the intake temperature and the discharge one is more than 8C (Cooling) or reversely (Heating).
Thermometer
R

3) Selection of the slide switch according to installation method

1. In case the indoor unit is installed on the floor, please change the side switch which is on the Main PCB Assembly to the 'BOTTOM' state. 2. In case the indoor unit is installed under the ceiling, please change the slide switch which is on the Main PCB Assembly to the ' CEILING' state. The initial state of the slide switch is set for the bottom installation.

38

Operation
(1) Name and Function-Remote controller
1) Cooling Model Remote Controller
Signal transmitter. Transmits the signals to the room air conditioner.

1 2 3 4
1

OPERATION DISPLAY Displays the operation conditions. START/STOP BUTTON Operation starts when this button is pressed and stops when the button is pressed again. OPERATION MODE SELECTION BUTTON Used to select the operation mode. ON/OFF TIMER BUTTONS Used to set the time of starting and stopping operation. TIME SETTING BUTTONS Used to adjust the time. TIMER SET/CANCEL BUTTONS Used to set the timer when the desired time is obtained and to cancel the Timer operation. AIR FLOW DIRECTION START/STOP BUTTON Used to stop or start louver movement and set the desired up/down airflow direction. SLEEP MODE AUTO BUTTON Used to set Sleep Mode Auto operation. AIR CIRCULATION BUTTON Used to circulate the room air without cooling or heating (turns indoor fan on/off). ROOM TEMPERATURE CHECKING BUTTON Used to check the room temperature. RESET BUTTON Used prior to resetting time or after replacing batteries.

5 6 7

7 2

8
ON OFF

4 5
SET CANCEL

8 9 10 11

9 10 11

39

2) Heat Pump Model Remote Controller

1
Signal transmitter. Transmits the signals to the room air conditioner.

OPERATION DISPLAY Displays the operation conditions. START/STOP BUTTON Operation starts when this button is pressed and stops when the button is pressed again. OPERATION MODE SELECTION BUTTON Used to select the operation mode. ON/OFF TIMER BUTTONS Used to set the time of starting and stopping operation. TIME SETTING BUTTONS Used to adjust the time. TIMER SET/CANCEL BUTTONS Used to set the timer when the desired time is obtained and to cancel the Timer operation. AIR FLOW DIRECTION START/STOP BUTTON Used to stop or start louver movement and set the desired up/down airflow direction. SLEEP MODE AUTO BUTTON Used to set Sleep Mode Auto operation. AIR CIRCULATION BUTTON Used to circulate the room air without cooling or heating (turns indoor fan on/off). ROOM TEMPERATURE CHECKING BUTTON Used to check the room temperature. RESET BUTTON Used prior to resetting time or after replacing batteries.

2 3 4
1

5 6
3 7

7
2
ON OFF

4 5
SET CANCEL

8 9 10 11

8 9 10 11

40

Disassembly of the parts (Indoor unit)

Warning : Disconnect the unit from power supply before making any checks. Be sure the power switch is set to OFF.

1. Remove the air filter. Pull the inlet grille slightly toward you. Pull out the air filter. (2 pieces)

Inlet Grille

2. Remove the girlle from chassis Remove the screws securing the side plate and push to the bottom-side. Unhook the hanger from the hanger screw at the left and the right side. Pick out the inlet grille.
R

1 4 Hanger Hanger Screw 2 3

3. Remove the lower air guide Remove a screw of both side fixing "barrier airguide". Remove the screws of both sides of the lower airguide. Remove the lower air-guide toward arrow mark by turning upwards as shown in figure.
R

Barrier Air guide Lower Air guide

41

4. Remove air guide upper, crossflow fan and motor. Remove the screws of both sides and center securing the upper air-guide. Remove 2 screws fastening the bracket of door switch.

Door Switch
R

Remove a bearing assembly by removing a screw and the bearing cover. Remove 4 screws securing the motor cover. Loosen the screw securing the crossflow fan to the fan motor shaft. (do not remove) Remove the crossflow fan by sliding it out from the shaft of fan motor.
Motor Cover

Bearing Cover
R

Bearing

5. Remove the control box Assembly. Disconnect the step motor connector, fan motor connector, display PCB connector, thermistor connector and door switch connector from the main PCB. If necessary, disconnect power supply cord and connecting cable from the terminal block and remove the cord clamp screw. Remove 2 screws securing the control box and pick out the control box carefully.

42

6. Remove the front panel. Remove the screws of both sides fixing the front panel. Push the upper side of front panel strongly to pull out the front panel from the inner hook of diffuser frame. Pull down the front panel carefully not so as to harm the display PCB wires and thermistor wires.

Diffuser frame Diffuser frame Hook Front Panel Front Panel

R

7. Remove the diffuser assembly. Remove the screws of both side of diffuser assembly. (4 pieces) Push the upper side of cabinet strongly to pull out the inner hook of diffuser frame from the cabinet hole. Take up the diffuser frame carefully not so as to harm the display PCB wires and the step motor wires.

Diffuser frame Hook Cabinet

8. Remove display PCB assembly. Remove the screws at the both side of display cover. If necessar y, disconnect the display PCB connector from PCB assembly. Remove 2 screws of PCB assembly.
Display Cover

43

9. Remove the vane-upper, vane-lower and step motor. Remove 2 screws securing the step motor assembly and pull it out from the vanes carefully. Unhook the vanes from the vane supporter and remove the upper vane and lower vane by pulling the center of vanes with care.

Step Motor Vane Supporter

Lower Vane

Upper Vane

10. Remove the drain pan assembly. Remove the both side of screws. (4 pieces) Pull out the drain pan assembly. Be careful not to harm to the EPS packing of drain pan and the tubings of evaporator.

11. Remove the evaporator. Remove the screws of both sides securing the EVA barrier-R/L on the side cabinet. Remove the screws which fasten the barrier on the evaporator and take out the barrier assembly. Remove the evaporator assembly by sliding toward arrow mark. (As shown in figure)

EVA. Barrier-L

Side Cabinet

EVA. Barrier-R

44

2-way, 3-way Valve

2-way Valve (Liquid Side) 3-way Valve (Gas Side or Liquid Side)

Hexagonal wrench (4mm) Flare nut Open position Closed position To piping connection To outdoor unit

Valve cap Open position Flare nut Closed position Pin To piping connection

Service Service port cap port

To outdoor unit

Works Shipping Air purging (Installation)

Shaft position Closed (with valve cap) Open (counter-clockwise)

Shaft position Closed (with valve cap) Closed (clockwise)

Service port Closed (with cap) Open (push-pin or with vacumm pump) Closed (with cap) Open (connected manifold gauge) Open (with Vaccum pump) Open (with charging cylinder) " "

1.

Operation Pumping down (Transfering) Evacuation (Servicing) Gas charging (Servicing) Pressure check (Servicing) Gas releasing (Servicing)

Open (with valve cap) Closed (clockwise)

Open (with valve cap) Open (counter-clockwise)

2.

3.

Open

Open

Open

Open

4.

5. 6.

Open Open

Open Open

45

1. Pumping down

Indoor unit

Liquid side 2-Way valve

Open

Outdoor unit

Gas side

Closed
3-Way valve

Lo
CLOSE CLOSE

Purge the air

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 gaug e 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.

46

1) Re-air purging
(Re-installation)

Indoor unit

Liquid side 2-Way valve

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.

47

2) Balance refrigerant of the 2-way, 3-way valves

(Gas leakage)

Indoor unit

Liquid side Outdoor unit 2-Way valve

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.

48

2. Evacuation
(All amount of refrigerant leaked)

Indoor unit

Liquid side Outdoor unit 2-Way valve

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.

49

3. Gas Charging
(After Evacuation)

Indoor unit

Liquid side 2-Way valve

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). 50

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 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 torque wrench to tighten the service port nut to a torque of 1.8 kg.m. Be sure to check for gas leakage.

Cycle Troubleshooting Guide

Trouble analysis
1. Check temperature difference between intake and discharge air and operating current. Temp. difference Current : approx. 0C : less than 80% of rated current All amount of refrigerant leaked out Check refrigeration cycle

Temp. Difference

Temp. difference Current

: approx. 8C : less than 80% of rated current

Refrigerant leakege Clog of refrigeration cycle Defective compressor

Operating Current

Temp. difference Current

: less than 8C : over the rated current

Excessive amount of refrigerant

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.

51

Electronic Parts Troubleshooting Guide

Possible Trouble 1
: The unit does not operate.

Is the input voltage of transformer AC220V? YES Is the output voltage of transformer about AC14V? YES

NO

Check the FUSE and the wiring diagram Check the RY-COMP PIN 3 and CN-4WAY PIN 1 Is shorted the transformer output? YES NO Check the main P.C.B pattern Exchange the transformer Exchange D01D-D05D

NO

Is the input voltage of IC01D DC14V? YES Is the output voltage of IC01D DC12V? YES

NO

NO

Exchange IC01D

Is the output voltage of IC02D DC5V? YES

NO

Exchange IC02D

Is the PIN 29 of Micom DC5V? YES

NO

Exchange IC01A

Is the PIN 55,64 of Micom DC5V? YES Exchange Micom

NO

Check the 5V P.C.B pattern

52

Possible Trouble 2

: The indoor fan does not operate.

Is it DRY mode?

YES

Does the temperature set all right? YES

NO

Adjust set temperature

NO

Is it the HOT mode? NO

YES

Does the temperature set all right? YES

NO

Adjust set temperature

Is IC02M operated normally? YES

NO

Exchange IC02M

Is the each S.S.R any problem? NO

YES Exchange S.S.R

Check the fan motor and connector. (CN-FAN)

53

Possible Trouble 3

: Up/Down Air direction louver does not operate.

Is IC01M operated normally? YES

NO

Exchange IC01M

Is the PIN 1 of CN-UP/DOWN DC12V? YES Check the step motor and connector (CN-UP/DOWN 1,2)

NO

Check the main P.C.B DC12V pattern

Possible Trouble 4

: Remote controller does not operate.

Is the battery consumed much? NO

YES

Exchange the battery

Is the PIN 8 of CN-DISP DC5V? YES

NO

Check the main P.C.B DC5V pattern

Is the connection of CN-DISP all right? YES Exchange receiver ass'y

NO

Connect CN-DISP exactly

54

Possible Trouble 5

: Ineffective Heating

Is 4way-valve operated?

NO

Check RY-4WAY

YES

Is IC02M operated normally? YES Check the RY-4WAY and 4way-valve

NO

Exchange IC02M

Possible Trouble 6

: The unit does not operate by forced operation switch.

Is the F/OP key any problem? NO Check P.C.B pattern check

YES

Exchange F/OP key

55

Electronic control device

(1) MAIN P.C.B ASM (LV-B1861HL/B2461HL P/No.: 6871A20042A) (LV-B1864HL/B2464HL P/No.: 6871A20042K) (LV-B1861CL/B2461CL P/No.: 6871A20042D) (LV-B1864CL/B2464CL P/No.: 6871A20042D)

(2) DISPLAY P.C.B ASM (P/No.: 6871AQ3263A)

56

Schematic Diagram

57

RY-OUTFAN

RY-4WAY

146811

1. Indoor Unit

159911

130911 346811 166000

159911

352150

235450 237900 137213 261704 352115 268712 W0CZZ

Exploded View and Replacement Parts List

58
354211 330870 359010 152302

267110 35211A 263230

137213

135314

342800

Parts List (Cooling Only Models)

PART No.
LOCATION NO. 130911 135314 137213 137213 146811 152302 159911 159911 166000 235450 237900 261704 263230 267110 268712 330870 342800 346811 352115 35211A 352150 354211 359010 W0CZZ DESCRIPTION CABINET ASSY GRILLE ASSY, INLET SUB PANEL ASSY, SIDE PWB(PCB) ASSY, MAIN MOTOR ASSY, STEP FILTER(MECH), A/C VANE ASSY, HORIZONTAL VANE ASSY SWITCH, PUSH DISPLAY ASSY (MECH) WINDOW, DISPLAY TRANSFORMER, POWER THERMISTOR ASSY REMOTE CONTROLLER ASSY PWB(PCB) ASSY, DISPLAY DRAIN PAN ASSY BEARING MOTOR ASSY, INDOOR TUBE ASSY, EVA-IN TUBE ASSY, SUCTION INDOOR HOSE ASSY, DRAIN EVAPORATOR ASSY FAN ASSY, CROSS FLOW CAPACITOR LV-B1861CL LV-B1864CL LV-B2461CL LV-B2464CL 3091AP2533A 5237AP2817B 3720AP2767P 6871A20042D 4681AR2727G 5230AP7093A 5991AP2867B 5991AP7334C 6600AP2059B 3545AP7224A 3790AP7080A 6171AQ3198E 6323AQ2333J 6711A20010J 6871AQ3263A 3087AP7233A 3H02821A 4681AP2306E 5211AP2810A 5211AP2813A 5251AP2460B 5421AP2812A 5901AR2351E 3H00671A REMARK

3091AP2533A 5237AP2817B 3720AP2767P 6871A20042D 6871A20042L

4681AR2727G 5230AP7093A 5991AP2867B 5991AP7334C 6600AP2059B 3545AP7224A 3790AP7080A 6171AQ3198E 6323AQ2333Y 6711A20010J 6871AQ3263A 3087AP7233A 3H02821A 4681AP2306G 5211AP2810G 5211AP2810K

5211AP2813C 5251AP2460B 5421AP2812B 5901AR2351E 3H00671A

59

Parts List (Heat Pump Models)

PART No.
LOCATION NO. 130911 135314 137213 137213 146811 152302 159911 159911 166000 235450 237900 261704 263230 267110 268712 330870 342800 346811 352115 35211A 352150 354211 359010 W0CZZ DESCRIPTION LV-B1861HL CABINET ASSY GRILLE ASSY, INLET SUB PANEL ASSY, SIDE PWB(PCB) ASSY, MAIN MOTOR ASSY, STEP FILTER(MECH), A/C VANE ASSY, HORIZONTAL VANE ASSY SWITCH, PUSH DISPLAY ASSY (MECH) WINDOW, DISPLAY TRANSFORMER, POWER THERMISTOR ASSY REMOTE CONTROLLER ASSY PWB(PCB) ASSY, DISPLAY DRAIN PAN ASSY BEARING MOTOR ASSY, INDOOR TUBE ASSY, EVA-IN TUBE ASSY, SUCTION INDOOR HOSE ASSY, DRAIN EVAPORATOR ASSY FAN ASSY, CROSS FLOW CAPACITOR LV-B1864HL LV-B2461HL LV-B2464HL REMARK

3091AP2533A 5237AP2817B 3720AP2767P

3091AP2533A 3091AP2533A 5237AP2817B 5237AP2817B 3720AP2767P 3720AP2767P

6871A20042A 6871A20042K 6871A20042A 6871A20042K 4681AR2727G 5230AP7093A 5991AP2867B 5991AP7334C 6600AP2059B 3545AP7224A 3790AP7080A 6171AQ3198E 6323AQ2333J 6711A20010K 6871AQ3263A 3087AP7233A 3H02821A 4681AP2306G 4681AR2727G 4681AR2727G 5230AP7093A 5230AP7093A 5991AP2867B 5991AP2867B 5991AP7334C 5991AP7334C 6600AP2059B 6600AP2059B 3545AP7224A 3545AP7224A 3790AP7080A 3790AP7080A 6171AQ3198E 6171AQ3198E 6323AQ2333Y 6323AQ2333Y 6711A20010K 6711A20010K 6871AQ3263A 6871AQ3263A 3087AP7233A 3087AP7233A 3H02821A 3H02821A

4681AP2306E 4681AP2306E

5211AP2810C 5211AP2810K 5211AP2810E 5211AP2810J 5211AP2813C 5251AP2460B 5421AP2812B 5901AR2351E 3H00671A 5211AP2813A 5211AP2813A 5251AP2460B 5251AP2460B 5421AP2812A 5421AP2812A 5901AR2351E 5901AR2351E 3H00671A 3H00671A

60

554030

435512 437212 552201

2. Outdoor Unit

546810 552201 559010 W0CZZ-2

437210 W0CZZ-1 268711 263230

61
561410 447910 554160 552570 430410

435511 W6640 668713 552202 566000 W0CZZ-3

552203

552203

Parts List (Cooling Only Models)

PART No.
LOCATION NO. 430410 435511 435512 437210 437212 447910 546810 552101 552201 552203 552203 552570 554030 554160 559010 W0CZZ W6640 W6640 DESCRIPTION LV-B1861CL BASE ASSY, WELD(OUTDOOR) COVER ASSY, CONTROL(OUTDOOR) COVER ASSY, TOP(OUTDOOR) PANEL ASSY, FRONT(OUTDOOR) PANEL ASSY, REAR BARRIER ASSY, OUTDOOR MOTOR ASSY, OUTDOOR TUBE, CAPILLARY TUBE, CAPILLARY VALVE, SERVICE VALVE, SERVICE MUFFLER CONDENSER ASSY, BENT COMPRESSOR FAN ASSY, PROPELLER CAPACITOR TERMINAL BLOCK TERMINAL BLOCK 3A90082B 5402AR2347H 2A00715N 5416A20016A 1A00195B 6120AR2194F 6120AR2194K 2H01890K 2H02479B 3041A30003K LV-B1864CL 3041A30003U LV-B2461CL LV-B2464CL 3041A30003K 3A01919B 3H03266K 3721A20005F 3720AP0003D 2H02110A 4681A20013D 3H01535Y 2H01890D 2A00392K 2H02479B 5402AR2347D 2A00715P 1A00195B 6120AR2359X 4G00103C 3H00390B REMARK

3A01919B 3H03266K 3721A20005F 3720AP0003D 2H02110A 4681A20013A 5424AR3448C 4681A20013D 5424AR3448E

4G00103C 3H00390B

62

Parts List (Heat Pump Models)

PART No.
LOCATION NO. 263230 268711 430410 435511 435512 437210 437212 447910 546810 552201 552201 552202 552203 552203 552570 554030 554160 559010 561410 566000 649950 W0CZZ-1 W0CZZ-2 W6640 W6640 W0CZZ-3 668713 DESCRIPTION LV-B1861HL THERMISTOR ASSY PWB(PCB) ASSY, DEICER BASE ASSY, WELD[OUTDOOR] 3Q35015E 6871A20015F LV-B1864HL LV-B2461HL 3Q35015H 6871A20015Q LV-B2464HL REMARK

3041A30003K 3041A30003U 3A01919B 3H03266K

3041A30003K 3041A30003K 3A01919B 3H03266K 3A01919B 3H03266K

COVER ASSY, CONTROL(OUTDOOR) 3551A30007W COVER ASSY, TOP(OUTDOOR) PANEL ASSY, FRONT(OUTDOOR) PANEL ASSY, REAR BARRIER ASSY, OUTDOOR MOTOR ASSY, OUTDOOR VALVE, CHECK TUBE, CAPILLARY VALVE, REVERSING VALVE, SERVICE VALVE, SERVICE MUFFLER CONDENSER ASSY, BENT COMPRESSOR FAN ASSY, PROPELLER COIL ASSY, REVERSING VALVE SWITCH, PRESSURE CONTROL BOX, OUTDOOR CAPACITOR CAPACITOR TERMINAL BLOCK TERMINAL BLOCK CAPACITOR PCB, SOFT START 3H03266J

3721A20005F 3720AP0003D 2H02110A

3721A20005F 3721A20005F 3720AP0003D 3720AP0003D 2H02110A 2H02110A

4681A20013F 4681A20013D 4681A20013D 4681A20013D 3A01020H 3H01535G 3H01535R 3A01020H 3H01535R 3A02027A 2A00392E 2H02479B 3A90082A 3A01020H 3H01535R 3A02027A 2A00392E 2H02479B 3A90082A

3A02027A 2H01890D 2H02479B 3A90082A 5211A20030C

5402AR2347B 5403A20022F

5403A20022F 5403A20022F

5416AR1411G 5416A20016A 5416AR1411H 5416AR1411H 1A00195B 3A02028Y 3A02524C 4995A2424U 4995A2022Z 2A00986D 2A00986W 4G00103A 3H00390B 6120AR2194K 2A00986A 2A00986D 3H00390B 1A00195B 3A02028Y 3A02524C 4995A2424Z 1A00195B 3A02028Y 4995A20022Z 4995A10040B Only Australia 6120AR2194K 4G00103A 3H00390B 0CZZAP3478C Only Australia 6871A20052B Only Australia

63

P/No.: 3828A30027H

September, 2001 Printed in Korea